1. DL manuals
  2. Suzuki
  3. Offroad Vehicle
  4. kq500
  5. Manual

Suzuki kq500 Manual

Summary of kq500

  • Page 1

    Foreword this manual contains an introductory description on the suzuki lt-a500xp/z and procedures for its inspection/ service and overhaul of its main components. Other information considered as generally known is not included. Read the general information section to familiarize yourself with the v...

  • Page 3: Table of Contents

    00 0 1 2 3 4 5 6 9 precautions............................................................... 00-i precautions ............................................................ 00-1 general information ................................................... 0-i general information ..............................

  • Page 5: Section 00

    Table of contents 00- i 00 section 00 contents precautions precautions ...............................................00-1 precautions........................................................... 00-1 warning / caution / note..................................... 00-1 general precautions .................

  • Page 6: Precautions

    00-1 precautions: precautions precautions precautions warning / caution / note b931h20000001 please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words warning, caution and note have special meanings. Pay special attention to the message...

  • Page 7

    Precautions: 00-2 • never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger than required to slip the circlip over the shaft. After installing a circlip, always ensure that it is completely seated in its groove and securely fitted. • use a torque wrench to ti...

  • Page 8

    00-3 precautions: • when connecting meter probe from the terminal side of the coupler (where connection from harness side not being possible), use extra care not to force and cause the male terminal to bend or the female terminal to open. Connect the probe as shown to avoid opening of female termina...

  • Page 9

    Precautions: 00-4 • be careful not to touch the electrical terminals of the electronic parts (ecm, etc.). The static electricity from your body may damage these. • when disconnecting and connecting the coupler, make sure to turn off the ignition switch, or electronic parts may get damaged. • never a...

  • Page 10

    00-5 precautions: • before measuring voltage at each terminal, check to make sure that battery voltage is 11 v or higher. Terminal voltage check with a low battery voltage will lead to erroneous diagnosis. • never connect any tester (voltmeter, ohmmeter, or whatever) to the electronic unit when its ...

  • Page 11

    Precautions: 00-6 4) using continuity inspect or voltage check procedure as described below, inspect the wire harness terminals for open circuit and poor connection. Locate abnormality, if any. Continuity check 1) measure resistance across coupler “b” (between “a” and “c” in figure). If no continuit...

  • Page 12

    00-7 precautions: short circuit check (wire harness to ground) 1) disconnect the negative (–) cable from the battery. 2) disconnect the connectors/couplers at both ends of the circuit to be checked. Note if the circuit to be checked branches to other parts as shown, disconnect all connectors/ couple...

  • Page 13

    Precautions: 00-8 using the testers • incorrectly connecting the (+) and (–) probes may cause the inside of the tester to be burnout. • if the voltage and current are not known, make measurements using the highest range. • when measuring the resistance with the multi-circuit tester (1), ∞ will be sh...

  • Page 14

    00-9 precautions:.

  • Page 15: Section 0

    Table of contents 0- i 0 section 0 contents general information general information ................................ 0a-1 general description .............................................0a-1 symbols .............................................................. 0a-1 abbreviations .....................

  • Page 16: General Information

    0a-1 general information: general information general information general description symbols b931h20101001 listed in the table below are the symbols indicating instructions and other information necessary for servicing. The meaning of each symbol is also included in the table. Abbreviations b931h20...

  • Page 17

    General information: 0a-2 fp relay: fuel pump relay g: gen: generator gnd: ground gp switch: gear position switch h: hc: hydrocarbons i: iap sensor: intake air pressure sensor (iaps) iat sensor: intake air temperature sensor (iats) ig: ignition isc valve: idle speed control valve (iscv) j: jaso: jap...

  • Page 18

    0a-3 general information: vehicle side view b931h20101004 note difference between illustration and actual vehicle may exist depending on the markets. Suzuki lt-a500xp (2009-model) right side left side vehicle identification number b931h20101005 the frame serial number or v.I.N. (vehicle identificati...

  • Page 19

    General information: 0a-4 engine oil (for other countries) oil quality is a major contributor to your engine’s performance and life. Always select good quality engine oil. Use of sf/sg or sh/sj in api with ma in jaso. Suzuki recommends the use of sae 10w-40 engine oil. If sae 10w-40 engine oil is no...

  • Page 20

    0a-5 general information: country and area codes b931h20101009 the following codes stand for the applicable country(-ies) and area(-s). Wire color symbols b931h20101010 code country or area effective frame no. Lt-a500xpk9 (p-17) sweden 5saam45p97100001 – lt-a500xpk9 (p-24) australia lt-a500xpk9 (p-2...

  • Page 21

    General information: 0a-6 warning, caution and information labels location b931h20101011 5 14 17, 18 11 9 6 3 7 8 10 12, 13 15, 16 4 1, 20, 21 22, 23 24 19 25 2, 26, 27 [a] i931h1010010-03 1. Certification plate (english) for p-24, 33 15. Front carrier warning label (english) for p-24, 33 2. Informa...

  • Page 22

    0a-7 general information: component location electrical components location b931h20103001 1 2 3 4 5 6 7 8 12 11 15 16 10 9 17 13 14 18 i931h1010005-03 1. Battery 7. Drive relay 13. Ignition switch 2. Starter relay/main fuse 8. Mode select switch coupler 14. Power source 3. Fuse box 9. Starter motor ...

  • Page 23

    General information: 0a-8 37 36 19 20 22 21 24 26 25 31 32 27 28 29 23 30 34 35 33 i931h1010006-05 19. Cooling fan thermo-switch 26. Parking/rear brake switch 33. Speed sensor 20. Resister 27. Regulator/rectifier 34. Ckp sensor 21. 4wd/diff-lock actuator diode 28. Parking brake relay 35. Generator 2...

  • Page 24

    0a-9 general information: specifications specifications b931h20107001 note these specifications are subject to change without notice. Dimensions and dry mass engine drive train item specification remark overall length 2 115 mm (83.3 in) p-28, 33 2 165 mm (85.2 in) p-17, 24 overall width 1 210 mm (47...

  • Page 25

    General information: 0a-10 chassis electrical capacities item specification remark front suspension independent, double wishbone, coil spring, oil damped rear suspension independent, double wishbone, coil spring, oil damped front wheel travel 170 mm (6.7 in) rear wheel travel 195 mm (7.7 in) caster ...

  • Page 26

    0a-11 general information: special tools and equipment special tool b931h20108001 09900–06107 snap ring remover (open type) 09900–06108 snap ring remover (close type) 09900–20101 vernier calipers (150 mm) 09900–20102 vernier calipers (200 mm) 09900–20202 micrometer (25 – 50 mm) 09900–20204 micromete...

  • Page 27

    General information: 0a-12 09913–10750 compression gauge adapter 09913–50121 oil seal remover 09913–60910 bearing and gear puller 09913–61510 bearing puller 09913–70210 bearing installer set (10 – 75) 09913–75520 bearing installing tool 09915–40620 oil filter wrench 09915–64512 compression gauge 099...

  • Page 28

    0a-13 general information: 09920–33540 clutch shoe remover 09920–53740 clutch sleeve hub holder 09921–20240 bearing remover set 09921–21910 bearing holder set 09922–31430 clutch spring compressor 09923–73210 bearing remover 09923–74511 bearing remover 09924–41830 bearing retainer wrench (50 mm) 0992...

  • Page 29

    General information: 0a-14 09930–82720 mode selection switch 09940–40211 fuel pressure gauge adapter 09940–40220 fuel pressure gauge attachment 09940–92430 rear axle nut wrench (36×36 mm) 09941–34513 bearing installer 09941–51012 ring locknut wrench 09941–53610 front fork oil seal hammer 09942–72410...

  • Page 30: Maintenance and Lubrication

    0b-1 maintenance and lubrication: general information maintenance and lubrication precautions precautions for maintenance b931h20200001 the “periodic maintenance schedule chart” lists the recommended intervals for all the required periodic service work necessary to keep the vehicle operating at peak...

  • Page 31

    Maintenance and lubrication: 0b-2 lubrication points b931h20205002 proper lubrication is important for smooth operation and long life of each working part of the vehicle. Major lubrication points are indicated as follows. Note • before lubricating each part, clean off any rusty spots and wipe off an...

  • Page 32

    0b-3 maintenance and lubrication: repair instructions air cleaner element inspection and cleaning b931h20206001 inspect and clean element every 1 000 km (600 miles, 3 months) inspection 1) remove the air cleaner element. Refer to “air cleaner element removal and installation: in section 1d”. 2) insp...

  • Page 33

    Maintenance and lubrication: 0b-4 exhaust pipe bolt and muffler bolt inspection b931h20206002 tighten exhaust pipe bolts, muffler bolt and nut initially at 200 km (100 miles, 1 month) and every 1 000 km (600 miles, 3 months) thereafter check the exhaust pipe bolts, muffler bolts and nut to the speci...

  • Page 34

    0b-5 maintenance and lubrication: 5) remove the spark plug cap and spark plug. Refer to “spark plug cap and spark plug removal and installation: in section 1h”. Note valve clearance is to be checked when the engine is cold. The intake and exhaust valves must be checked and adjusted when the piston i...

  • Page 35

    Maintenance and lubrication: 0b-6 2) after inspect and adjust the clearance, apply grease to the valve timing inspection cap o-rings and install the inspection caps (1). : grease 99000–25010 (suzuki super grease a or equivalent) caution ! Use the new o-rings to prevent oil leakage. 3) tighten the va...

  • Page 36

    0b-7 maintenance and lubrication: spark plug gap 1) remove the spark plug. Refer to “spark plug cap and spark plug removal and installation: in section 1h”. 2) measure the spark plug gap using a wire gauge. Adjust the spark plug gap if necessary. Spark plug gap 0.7 – 0.8 mm (0.028 – 0.031 in) 3) aft...

  • Page 37

    Maintenance and lubrication: 0b-8 4) tighten the muffler end cover nut (3) to the specified torque. Tightening torque muffler end cover nut (a): 11 n·m (1.1 kgf-m, 8.0 lbf-ft) 5) after finishing the spark arrester cleaning, reinstall the removed parts. Fuel line inspection b931h20206007 inspect fuel...

  • Page 38

    0b-9 maintenance and lubrication: engine oil replacement 1) place the vehicle on a level ground and set the brake lock. 2) remove the engine side cover. Refer to “front side exterior parts removal and installation: in section 9d”. 3) place an oil pan below the engine, and drain engine oil by removin...

  • Page 39

    Maintenance and lubrication: 0b-10 oil filter replacement 1) drain engine oil as described in the engine oil replacement procedure. 2) remove left inner cover. Refer to “front side exterior parts removal and installation: in section 9d”. 3) remove the oil filter (1) using the special tool. Special t...

  • Page 40

    0b-11 maintenance and lubrication: 3) tighten the oil level plug (1) and oil filler plug (2) to the specified torque. Caution ! Replace the gasket washers with new ones. Tightening torque front differential gear oil level plug (a): 8 n·m ( 0.8 kgf-m, 5.7 lbf-ft) tightening torque front differential ...

  • Page 41

    Maintenance and lubrication: 0b-12 final gear oil inspection b931h20206011 inspect final gear oil every 2 000 km (1 200 miles, 6 months) 1) place the vehicle on a level ground. 2) remove the filler plug (1), and inspect the oil level. If the oil level is below, add fresh oil until the oil level reac...

  • Page 42

    0b-13 maintenance and lubrication: throttle cable play inspection and adjustment b931h20206013 inspect throttle cable play initially at 200 km (100 miles, 1 month) and every 1 000 km (600 miles, 3 months) thereafter inspect and adjust the throttle cable play “a” as follows. Throttle cable play “a” 3...

  • Page 43

    Maintenance and lubrication: 0b-14 3) remove the left inner fender. Refer to “front side exterior parts removal and installation: in section 9d”. 4) remove the front under cover. Refer to “under cover removal and installation: in section 9d”. 5) place a pan below the water pump, and then drain the e...

  • Page 44

    0b-15 maintenance and lubrication: radiator hoses inspection inspect radiator hoses every 2 000 km (1 200 miles, 6 months) inspect the radiator hoses for damage and engine coolant leakage. If any defects are found, replace them with new ones. Drive v-belt inspection and replacement b931h20206016 ins...

  • Page 45

    Maintenance and lubrication: 0b-16 drive shaft boots inspection b931h20206017 inspect drive shaft initially at 200 km (100 miles, 1 month) and every 1 000 km (600 miles, 3 months) thereafter • check the driveshaft boots for twist and grease leak. If any defects are found, replace the defective parts...

  • Page 46

    0b-17 maintenance and lubrication: front brake pads check the extent of front brake pad wear can be checked by observing the grooved limit line “a” on the pad. When the wear exceeds the grooved limit line, replace the pads with new ones. Refer to “front brake pad replacement: in section 4b”. Caution...

  • Page 47

    Maintenance and lubrication: 0b-18 brake pedal free travel inspection inspect and adjust the rear brake pedal free travel “a” as follows. Rear brake pedal free travel “a” 20 – 30 mm (0.8 – 1.2 in) adjustment • turn the adjuster nut (1) so the rear brake pedal has 20 – 30 mm (0.8 – 1.2 in) free trave...

  • Page 48

    0b-19 maintenance and lubrication: 5) after adjusting the play, check that the rear wheels roll freely without applying the brake, the transmission in neutral and the rear wheels off the ground. Readjust the rear brake lever if the rear wheels could not roll freely. Rear brake friction plate wear li...

  • Page 49

    Maintenance and lubrication: 0b-20 steering system inspection b931h20206022 inspect steering system initially at 200 km (100 miles, 1 month) and every 1 000 km (600 miles, 3 months) thereafter steering should be adjusted properly for smooth turning of handlebars and safe running. 1) place the vehicl...

  • Page 50

    0b-21 maintenance and lubrication: 5) after adjustment has been made, tighten the four lock-nuts to the specified torque. Tightening torque tie-rod lock-nut (a): 29 n·m (2.9 kgf-m, 21.0 lbf- ft) suspensions inspection b931h20206024 inspect suspension every 2 000 km (1 200 miles, 6 months) 1) support...

  • Page 51

    Maintenance and lubrication: 0b-22 6 steering shaft lower nut 162 n ⋅m (16.2 kgf-m, 117.0 lbf-ft) 7 tie-rod end nut 29 n ⋅m (2.9 kgf-m, 21.0 lbf-ft) 8 steering shaft upper nut 120 n ⋅m (12.0 kgf-m, 87.0 lbf-ft) 9 tie-rod lock-nut 29 n ⋅m (2.9 kgf-m, 21.0 lbf-ft) (e) 7 (d) 6 i931h1020060-02 (f) 8 i93...

  • Page 52

    0b-23 maintenance and lubrication: 16 tie-rod end nut 29 n ⋅m (2.9 kgf-m, 21.0 lbf-ft) 17 steering knuckle end nut (upper and lower) 29 n ⋅m (2.9 kgf-m, 21.0 lbf-ft) 18 front shock absorber mounting nut (lower) 60 n ⋅m (6.0 kgf-m, 43.5 lbf-ft) 19 front shock absorber mounting bolt (upper) 55 n ⋅m (5...

  • Page 53

    Maintenance and lubrication: 0b-24 27 rear brake case bolt 26 n ⋅m (2.6 kgf-m, 19.0 lbf-ft) 28 rear brake cam lever nut 11 n ⋅m (1.1 kgf-m, 8.0 lbf-ft) 29 rear shock absorber mounting nut (upper and lower) 60 n ⋅m (6.0 kgf-m, 43.5 lbf-ft) 30 rear suspension arm pivot nut (upper and lower) 60 n ⋅m (6...

  • Page 54

    0b-25 maintenance and lubrication: compression pressure check b931h20206026 refer to “compression pressure check: in section 1d”. Oil pressure check b931h20206027 refer to “oil pressure check: in section 1e”. Sds check b931h20206028 refer to “sds check: in section 1a”. Automatic clutch inspection b9...

  • Page 55

    Maintenance and lubrication: 0b-26 specifications tightening torque specifications b931h20207001 note the specified tightening torque is described in the following. “chassis bolt and nut inspection (page 0b-21)” reference: for the tightening torque of fastener not specified in this section, refer to...

  • Page 56

    0b-27 maintenance and lubrication: special tool b931h20208002 09900–20803 09900–20805 thickness gauge tire depth gauge )(page 0b-5) / )(page 0b- 5) )(page 0b-19) 09900–25008 09900–26006 multi circuit tester set engine tachometer )(page 0b-25) )(page 0b-25) / )(page 0b-25) 09915–40620 09917–14910 oil...

  • Page 57: Service Data

    Service data: 0c-1 general information service data specifications service data b931h20307001 valve + valve guide unit: mm (in) camshaft + cylinder head unit: mm (in) item standard limit valve diam. In. 30.6 (1.20) — ex. 27.0 (1.06) — valve clearance (when cold) in. 0.05 – 0.10 (0.002 – 0.004) — ex....

  • Page 58

    0c-2 service data: cylinder + piston + piston ring unit: mm (in) conrod + crankshaft unit: mm (in) oil pump clutch unit: mm (in) item standard limit compression pressure (automatic-decomp. Actuated) approx. 1 000 kpa (10.0 kgf/cm 2 , 142 psi) — piston-to-cylinder clearance 0.030 – 0.040 (0.0012 – 0....

  • Page 59

    Service data: 0c-3 drive train unit: mm (in) except ratio thermostat + radiator + fan + coolant item standard limit automatic transmission ratio variable change (2.902 – 0.779) — secondary reduction ratio 2.733 (41/19 x 19/15) — final reduction ratio front 3.600 (36/10) — rear 3.600 (36/10) — transf...

  • Page 60

    0c-4 service data: injector + fuel pump + fuel pressure regulator fi sensors throttle body item specification note injector resistance 11 – 13 Ω at 20 °c (68 °f) fuel pump discharge amount 55.5 ml (1.88/1.95 us/lmp qt) and more/10 sec. Fuel pressure regulator operating set pressure approx. 294 kpa (...

  • Page 61

    Service data: 0c-5 electrical unit: mm (in) wattage unit: w item standard/specification note spark plug type ngk: cr6e denso: u20esr-n gap 0.7 – 0.8 (0.028 – 0.031) spark performance over 8 (0.3) at 1 atm. Ignition coil resistance primary 0.1 – 0.6 Ω terminal – ground secondary 12 – 19 k Ω plug cap ...

  • Page 62

    0c-6 service data: brake + wheel unit: mm (in) tire unit: mm (in) suspension fuel + oil item standard/specification limit rear brake pedal height 12.5 – 22.5 (0.5 – 0.9) — rear brake pedal free travel 20 – 30 (0.8 – 1.2) — front brake disc thickness 3.3 – 3.7 (0.13 – 0.15) 3.0 (0.20) front brake dis...

  • Page 63

    Service data: 0c-7 tightening torque list b931h20307002 engine item n ⋅m kgf-m lbf-ft spark plug 11 1.1 8.0 air cleaner box mounting bolt 4.5 0.45 3.0 cylinder head cover bolt 10 1.0 7.0 rocket arm shaft bolt 28 2.8 20.0 intake pipe bolt 9 0.9 6.5 cylinder head bolt (m8) 25 2.5 18.0 cylinder head bo...

  • Page 64

    0c-8 service data: drive train fi system and fuel system cooling system item n ⋅m kgf-m lbf-ft 4wd/diff-lock actuator mounting bolt 10 1.0 7.0 front drive (differential) gear case cover bolt 12 1.2 8.5 front drive (differential) gear case mounting nut 50 5.0 36.0 front differential gear oil level pl...

  • Page 65

    Service data: 0c-9 chassis item n ⋅m kgf-m lbf-ft handlebar upper clamp bolt 26 2.6 19.0 handlebar holder nut 60 6.0 43.5 rear brake lever holder clamp bolt 10 1.0 7.5 throttle lever case clamp bolt 4 0.4 3.0 throttle lever case screw 2 0.2 1.5 eps body assembly mounting bolt 26 2.6 19.0 eps body as...

  • Page 66

    0c-10 service data: tightening torque chart for other bolts and nuts not listed in the preceding page, refer to this chart: bolt diameter “a” (mm) conventional or “4” marked bolt “7” marked bolt n ⋅m kgf-m lbf-ft n ⋅m kgf-m lbf-ft 4 1.5 0.15 1.0 2.3 0.23 1.5 5 3 0.3 2.0 4.5 0.45 3.0 6 5.5 0.55 4.0 1...

  • Page 67: Section 1

    Table of contents 1- i 1 section 1 contents engine precautions .................................................1-1 precautions............................................................. 1-1 precautions for engine.......................................... 1-1 engine general information and diagnos...

  • Page 68

    1-ii table of contents engine mechanical .................................. 1d-1 schematic and routing diagram ........................1d-1 throttle cable routing diagram..........................1d-1 diagnostic information and procedures ............1d-2 engine mechanical symptom diagnosis............

  • Page 69

    Table of contents 1-iii thermostat inspection ...................................... 1f-11 water pump components................................. 1f-12 water pump removal and installation.............. 1f-12 water pump disassembly and assembly ......... 1f-13 water pump related parts inspection .......

  • Page 70

    1-iv table of contents charging system ...................................... 1j-1 schematic and routing diagram ........................ 1j-1 charging system diagram .................................. 1j-1 component location ........................................... 1j-1 charging system component...

  • Page 71: Precautions

    Precautions: 1-1 engine precautions precautions precautions for engine b931h21000001 refer to “general precautions: in section 00” and “precautions for electrical circuit service: in section 00”..

  • Page 72

    1a-1 engine general information and diagnosis: engine engine general information and diagnosis general description injection timing description b931h21101001 injection time (injection volume) the factors to determine the injection time include the basic fuel injection time, which is calculated on th...

  • Page 73

    Engine general information and diagnosis: 1a-2 injection stop control self-diagnosis function the self-diagnosis function is incorporated in the ecm. The function has two modes, “user mode” and “dealer mode”. The user can only be notified by the lcd (display) panel and led (fi indicator light). To c...

  • Page 74

    1a-3 engine general information and diagnosis: dealer mode the defective function is memorized in the computer. Use the special tool’s coupler to connect to the mode select switch. The memorized malfunction code is displayed on lcd (display) panel. Malfunction means that the ecm does not receive sig...

  • Page 75

    Engine general information and diagnosis: 1a-4 schematic and routing diagram fi system wiring diagram b931h21102001 crankshaft position sensor (ckp sensor) engine coolant temperature sensor (ect sensor) t ip-over sensor (t o sensor) isc valve dif f-lock switch dif f-lock relay starter relay neutral ...

  • Page 76

    1a-5 engine general information and diagnosis: terminal alignment of ecm coupler b931h21102002 i931h1110006-01 terminal no. Circuit terminal no. Circuit 1 ignition coil (ig1) 18 ckp sensor signal (ckp-) 2 fuel injector (#1) 19 fuel pump relay (fp relay) 3 power source (+b) 20 power source for fuel i...

  • Page 77

    Engine general information and diagnosis: 1a-6 component location fi system parts location b931h21103001 “c” “b” “g” “e” “f” “a” “d” i931h1110007-05 “a”: ecm “c”: iap/tp/iat sensor “e”: speed sensor “g”: diff-lock relay “b”: isc valve “d”: ckp sensor “f”: combination meter “i” “j” “m” “k” “a” “l” “h...

  • Page 78

    1a-7 engine general information and diagnosis: diagnostic information and procedures engine symptom diagnosis b931h21104001 condition possible cause correction / reference item engine will not start or is hard to start (compression too low) valve clearance out of adjustment. Adjust. Worn valve guide...

  • Page 79

    Engine general information and diagnosis: 1a-8 engine stalls often (control circuit or sensor improperly operating) defective ecm. Replace. Defective fuel pressure regulator. Replace. Defective tp sensor. Replace. Defective iat sensor. Replace. Defective ckp sensor. Replace. Defective ect sensor. Re...

  • Page 80

    1a-9 engine general information and diagnosis: engine runs poorly in high speed range (defective control circuit or sensor) low fuel pressure. Repair or replace. Defective tp sensor. Replace. Defective iat sensors. Replace. Defective iap sensor. Replace. Defective ecm. Replace. Engine lacks power (d...

  • Page 81

    Engine general information and diagnosis: 1a-10 self-diagnostic procedures b931h21104002 use of mode select switch note • do not disconnect coupler from ecm, the battery cable from the battery, ecm ground wire harness from the engine or main fuse before confirming dtc (diagnostic trouble code) store...

  • Page 82

    1a-11 engine general information and diagnosis: use of sds note • do not disconnect the coupler from ecm, the battery cable from the battery, ecm ground wire harness from the engine or main fuse before confirming dtc (diagnostic trouble code) stored in memory. Such disconnection may erase the memori...

  • Page 83

    Engine general information and diagnosis: 1a-12 4) start the engine or crank the engine for more than 4 seconds. 5) check the dtc to determine the malfunction part. Refer to “dtc table (page 1a-18)”. Note • read the dtc (diagnostic trouble code) and show data when trouble (displaying data at the tim...

  • Page 84

    1a-13 engine general information and diagnosis: show data when trouble (displaying data at the time of dtc) b931h21104004 use of sds ecm stores the engine and driving conditions (in the form of data as shown in the figure) at the moment of the detection of a malfunction in its memory. This data is c...

  • Page 85

    Engine general information and diagnosis: 1a-14 1) click “show data when trouble” (1) to display the data. 2) click the drop down button (2), either “failure #1” or “failure #2” can be selected. 1 i718h1110269-02 2 i831g1110017-01.

  • Page 86

    1a-15 engine general information and diagnosis: sds check b931h21104005 using sds, sample the data at the time of new and periodic vehicle inspections. After saving the sampled data in the computer, file them by model and by user. The periodically filed data help improve the accuracy of troubleshoot...

  • Page 87

    Engine general information and diagnosis: 1a-16 data at 3 000 r/min under no load data at the time of racing approx. 3 000 r/min. Check the manifold absolute pressure xxx kpa. I931h1110068-01 throttle: quick wide open throttle: slowly open i931h1110069-01.

  • Page 88

    1a-17 engine general information and diagnosis: example of trouble three data; value 3 (current data 3), value 2 (past data 2) and value 1 (past data 1); can be made in comparison by showing them in the graph. Read the change of value by comparing the current data to the past data that have been sav...

  • Page 89

    Engine general information and diagnosis: 1a-18 dtc table b931h21104006 in the lcd (display) panel, the malfunction code is indicated from small code to large code. *1 to get the proper signal from the throttle position sensor, the sensor basic position is indicated in the lcd (display) panel. The m...

  • Page 90

    1a-19 engine general information and diagnosis: fi system troubleshooting b931h21104008 customer complaint analysis record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of an inspection form such as below will facilitate collectin...

  • Page 91

    Engine general information and diagnosis: 1a-20 note the above form is a standard sample. The form should be modified according to condition and characteristics of each market. Visual inspection prior to diagnosis using the mode select switch or sds, perform the following visual inspections. The rea...

  • Page 92

    1a-21 engine general information and diagnosis: malfunction code and defective condition table b931h21104009 malfunction code detected item detected failure condition check for c00 no fault — — c12 ckp sensor the signal does not reach ecm for 3 sec. Or more, after receiving the starter signal. Ckp s...

  • Page 93

    Engine general information and diagnosis: 1a-22 c24 ignition signal ckp sensor (pick-up coil) signal is produced, but signal from ignition coil is interrupted 8 times or more continuously. In this case, the code c24 (p0351) is indicated. Ignition coil, wiring/coupler connection, power supply from th...

  • Page 94

    1a-23 engine general information and diagnosis: dtc “c12” (p0335): ckp sensor circuit malfunction b931h21104010 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting note after repairing the trouble, clear the dtc using sds tool. Refer to “use of sds diagnos...

  • Page 95

    Engine general information and diagnosis: 1a-24 step action yes no 1 1) remove the left side cover. Refer to “front side exterior parts removal and installation: in section 9d”. 2) turn the ignition switch off. 3) check the ckp sensor coupler for loose or poor contacts. If ok, then measure the ckp s...

  • Page 96

    1a-25 engine general information and diagnosis: 1 5) if ok, then check the continuity between each terminal and ground. Special tool (a): 09900–25008 (multi-circuit tester set) ckp sensor continuity ∞Ω (infinity) (bl – ground, w – ground) are the resistance and continuity ok? Go to step 2. Replace t...

  • Page 97

    Engine general information and diagnosis: 1a-26 dtc “c13” (p0105-h/l): iap sensor circuit malfunction b931h21104011 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting caution ! When using the multi-circuit tester, do not strongly touch the terminal of the...

  • Page 98

    1a-27 engine general information and diagnosis: c13 (use of mode select switch) step action yes no 1 1) remove the left side cover. Refer to “front side exterior parts removal and installation: in section 9d”. 2) turn the ignition switch off. 3) check the iap sensor coupler for loose or poor contact...

  • Page 99

    Engine general information and diagnosis: 1a-28 p0105-h for iap sensor (use of sds) step action yes no 1 1) turn the ignition switch off. 2) remove the left side cover. Refer to “front side exterior parts removal and installation: in section 9d”. 3) check the iap sensor coupler for loose or poor con...

  • Page 100

    1a-29 engine general information and diagnosis: 1 6) disconnect the ecm coupler. Refer to “ecm removal and installation: in section 1c”. 7) insert the needle pointed probes to the lead wire coupler. 8) check the continuity between the g/b wire “b” and terminal “13”. If ok, then check the continuity ...

  • Page 101

    Engine general information and diagnosis: 1a-30 p0105-l for iap sensor (use of sds) step action yes no 1 1) turn the ignition switch off. 2) remove the left side cover. Refer to “front side exterior parts removal and installation: in section 9d”. 3) check the iap sensor coupler for loose or poor con...

  • Page 102

    1a-31 engine general information and diagnosis: 1 8) check the continuity between the r wire “a” and terminal “6”. Also, check the continuity between the g/b wire “b” and terminal “13”. Special tool (a): 09900–25008 (multi-circuit tester set) (b): 09900–25009 (needle pointed probe set) tester knob i...

  • Page 103

    Engine general information and diagnosis: 1a-32 3 1) turn the ignition switch off. 2) connect the iap sensor coupler. 3) insert the needle pointed probes to the lead wire coupler. 4) starter the engine at idle speed and measure the iap sensor output voltage at the wire side coupler between g/b wire ...

  • Page 104

    1a-33 engine general information and diagnosis: dtc “c14” (p0120-h/l): tp sensor circuit malfunction b931h21104012 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting caution ! When using the multi-circuit tester, do not strongly touch the terminal of the ...

  • Page 105

    Engine general information and diagnosis: 1a-34 c14 (use of mode select switch) step action yes no 1 1) remove the left side cover. Refer to “front side exterior parts removal and installation: in section 9d”. 2) turn the ignition switch off. 3) check the tp sensor coupler for loose or poor contacts...

  • Page 106

    1a-35 engine general information and diagnosis: p0120-h (use of sds) step action yes no 1 1) remove the left side cover. Refer to “front side exterior parts removal and installation: in section 9d”. 2) turn the ignition switch off. 3) check the tp sensor coupler for loose or poor contacts. If ok, th...

  • Page 107

    Engine general information and diagnosis: 1a-36 1 8) check the continuity between y wire “b” and terminal “14”. Also, check the continuity between b/br wire “c” and terminal “24”. Special tool (a): 09900–25008 (multi-circuit tester set) (b): 09900–25009 (needle pointed probe set) tester knob indicat...

  • Page 108

    1a-37 engine general information and diagnosis: p0120-l (use of sds) step action yes no 1 1) remove the left side cover. Refer to “front side exterior parts removal and installation: in section 9d”. 2) turn the ignition switch off. 3) check the tp sensor coupler for loose or poor contacts. If ok, th...

  • Page 109

    Engine general information and diagnosis: 1a-38 1 8) check the continuity between y wire “b” and terminal “14”. Also, check the continuity between r wire “a” and terminal “6”. Special tool (a): 09900–25008 (multi-circuit tester set) (b): 09900–25009 (needle pointed probe set) tester knob indication ...

  • Page 110

    1a-39 engine general information and diagnosis: 3 1) connect the tp sensor coupler. 2) insert the needle pointed probes to the lead wire coupler. 3) turn the ignition switch on. 4) measure the tp sensor output voltage at the coupler (between (+) y wire and (–) b/br wire) by opening the throttle leve...

  • Page 111

    Engine general information and diagnosis: 1a-40 dtc “c15” (p0115-h/l): ect sensor circuit malfunction b931h21104013 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting caution ! When using the multi-circuit tester, do not strongly touch the terminal of the...

  • Page 112

    1a-41 engine general information and diagnosis: c15 (use of mode select switch) step action yes no 1 1) remove the right side cover. Refer to “front side exterior parts removal and installation: in section 9d”. 2) turn the ignition switch off. 3) check the ect sensor coupler for loose or poor contac...

  • Page 113

    Engine general information and diagnosis: 1a-42 p0115-h (use of sds) step action yes no 1 1) remove the right side cover. Refer to “front side exterior parts removal and installation: in section 9d”. 2) turn the ignition switch off. 3) check the ect sensor coupler for loose or poor contacts. If ok, ...

  • Page 114

    1a-43 engine general information and diagnosis: p0115-l (use of sds) step action yes no 1 1) remove the left side cover. Refer to “front side exterior parts removal and installation: in section 9d”. 2) turn the ignition switch off. 3) check the ect sensor coupler for loose or poor contacts. If ok, t...

  • Page 115

    Engine general information and diagnosis: 1a-44 1 9) measure the output voltage between b/bl wire and ground. Special tool (a): 09900–25008 (multi-circuit tester set) (b): 09900–25009 (needle pointed probe set) tester knob indication voltage ( ) output voltage 0.1 – 4.6 v ((+) terminal: b/bl – (–) t...

  • Page 116

    1a-45 engine general information and diagnosis: dtc “c20” (p1752): diff-lock relay circuit malfunction b931h21104014 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting note after repairing the trouble, clear the dtc using sds tool. Refer to “use of sds di...

  • Page 117

    Engine general information and diagnosis: 1a-46 step action yes no 1 1) remove the left side cover and engine side cover. Refer to “front side exterior parts removal and installation: in section 9d”. 2) connect the disconnected couplers and battery. 3) turn the ignition switch off. 4) check the diff...

  • Page 118

    1a-47 engine general information and diagnosis: dtc “c21” (p0110-h/l): iat sensor circuit malfunction b931h21104015 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting caution ! When using the multi-circuit tester, do not strongly touch the terminal of the...

  • Page 119

    Engine general information and diagnosis: 1a-48 c21 (use of mode select switch) step action yes no 1 1) remove the left side cover. Refer to “front side exterior parts removal and installation: in section 9d”. 2) turn the ignition switch off. 3) check the iat sensor coupler for loose or poor contact...

  • Page 120

    1a-49 engine general information and diagnosis: p0110-h (use of sds) step action yes no 1 1) remove the left side cover. Refer to “front side exterior parts removal and installation: in section 9d”. 2) turn the ignition switch off. 3) check the iat sensor coupler for loose or poor contacts. If ok, t...

  • Page 121

    Engine general information and diagnosis: 1a-50 p0110-l (use of sds) step action yes no 1 1) turn the ignition switch off. 2) check the iat sensor coupler for loose or poor contacts. If ok, then check the iat sensor lead wire continuity. 3) disconnect the iat sensor coupler. 4) insert the needle poi...

  • Page 122

    1a-51 engine general information and diagnosis: 1 9) measure the output voltage between the dg wire and ground. Special tool (a): 09900–25008 (multi-circuit tester set) (b): 09900–25009 (needle pointed probe set) tester knob indication voltage ( ) iat sensor output voltage 1.88 – 3.06 v at 20 °c (68...

  • Page 123

    Engine general information and diagnosis: 1a-52 dtc “c23” (p1651-h/l): to sensor circuit malfunction b931h21104016 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting caution ! When using the multi-circuit tester, do not strongly touch the terminal of the ...

  • Page 124

    1a-53 engine general information and diagnosis: c23 (use of mode select switch) step action yes no 1 1) remove the air cleaner box. Refer to “air cleaner box removal and installation: in section 1d”. 2) turn the ignition switch off. 3) check the to sensor coupler for loose or poor contacts. If ok, t...

  • Page 125

    Engine general information and diagnosis: 1a-54 p1651-h (use of sds) step action yes no 1 1) remove the air cleaner box. Refer to “air cleaner box removal and installation: in section 1d”. 2) turn the ignition switch off. 3) check the to sensor coupler for loose or poor contacts. If ok, then check t...

  • Page 126

    1a-55 engine general information and diagnosis: 1 8) check the continuity between br/w wire “b” and terminal “10”. Also, check the continuity between b/br wire “c” and terminal “24”. Special tool (a): 09900–25008 (multi-circuit tester set) (b): 09900–25009 (needle pointed probe set) tester knob indi...

  • Page 127

    Engine general information and diagnosis: 1a-56 p1651-l (use of sds) step action yes no 1 1) remove the air cleaner box. Refer to “air cleaner box removal and installation: in section 1d”. 2) turn the ignition switch off. 3) check the to sensor coupler for loose or poor contacts. If ok, then check t...

  • Page 128

    1a-57 engine general information and diagnosis: step action yes no 1 9) check the continuity between r wire “a” and terminal “6”. Also, then check the continuity between br/w wire “b” and terminal “10”. Special tool (a): 09900–25008 (multi-circuit tester set) (b): 09900–25009 (needle pointed probe s...

  • Page 129

    Engine general information and diagnosis: 1a-58 2 1) connect the to sensor coupler. 2) insert the needle pointed probes to the lead wire coupler. 3) turn the ignition switch on. 4) measure the voltage at the wire side coupler between br/w and b/br wires. Also, measure the voltage when learning the v...

  • Page 130

    1a-59 engine general information and diagnosis: dtc “c24” (p0351): ignition coil circuit malfunction b931h21104017 note refer to “no spark or poor spark: in section 1h” for details. Dtc “c32” (p0201): fuel injector circuit malfunction b931h21104018 detected condition and possible cause wiring diagra...

  • Page 131

    Engine general information and diagnosis: 1a-60 step action yes no 1 1) remove the air cleaner box. Refer to “air cleaner box removal and installation: in section 1d”. 2) turn the ignition switch off. 3) check the injector coupler for loose or poor contacts. If ok, then measure the injector resistan...

  • Page 132

    1a-61 engine general information and diagnosis: 1 5) if ok, then check the continuity between each terminal and ground. Special tool (a): 09900–25008 (multi-circuit tester set) injector continuity ∞Ω (infinity) (terminal – ground) are the resistance and continuity ok? Go to step 2. Replace the injec...

  • Page 133

    Engine general information and diagnosis: 1a-62 dtc “c40” (p0505-h/l): isc valve circuit malfunction b931h21104019 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting caution ! • be careful not to disconnect at least 3 seconds after ignition switch is turn...

  • Page 134

    1a-63 engine general information and diagnosis: step action yes no 1 1) remove the air cleaner box. Refer to “air cleaner box removal and installation: in section 1d”. 2) turn the ignition switch off. 3) check the isc valve coupler for loose or poor contacts. If ok, then check the isc valve lead wir...

  • Page 135

    Engine general information and diagnosis: 1a-64 2 1) move the throttle body as shown. Refer to “throttle body removal and installation: in section 1d”. 2) measure the resistance between terminals “a” and “c”, terminals “b” and “d”. Special tool (a): 09900–25008 (multi-circuit tester set) isc valve r...

  • Page 136

    1a-65 engine general information and diagnosis: 2 3) if ok, then measure the resistance between terminals “a” and “b”, terminals “c” and “d”. Special tool (a): 09900–25008 (multi-circuit tester set) isc valve resistance approx. 31 Ω at 20 °c (68 °f) (terminal “a” – terminal “b”) (terminal “c” – term...

  • Page 137

    Engine general information and diagnosis: 1a-66 active control inspection (isc rpm control) check 1 1) set up the sds tool. (refer to the sds operation manual for further details.) 2) check that the engine is running. 3) click the “active control”. 4) click the “isc rpm control” (1). 5) check that t...

  • Page 138

    1a-67 engine general information and diagnosis: check 3 1) click the button (6) and increase the “spec” (2) to 1 600 rpm slowly. 2) check that the “desired idle speed” (3) is nearly equal to the “spec” (2). Also, check that the number of steps (5) in the isc valve position increases. Check 4 1) clic...

  • Page 139

    Engine general information and diagnosis: 1a-68 dtc “c41” (p230-h/l): fp relay circuit malfunction b931h21104020 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting note after repairing the trouble, clear the dtc using sds tool. Refer to “use of sds diagno...

  • Page 140

    1a-69 engine general information and diagnosis: c41 (use of mode select switch) p0230-h (use of sds) step action yes no 1 1) remove the seat. Refer to “seat removal and installation: in section 9d”. 2) turn the ignition switch to off. 3) check the fp relay coupler for loose or poor contacts. If ok, ...

  • Page 141

    Engine general information and diagnosis: 1a-70 p0230-l (use of sds) specifications service data b931h21107001 injector fi sensors + secondary throttle valve actuator step action yes no 1 1) turn the ignition switch to off. 2) remove the seat. Refer to “front side exterior parts removal and installa...

  • Page 142

    1a-71 engine general information and diagnosis: special tools and equipment special tool b931h21108001 09900–25008 )(page 1a-51) / )(page 1a-51) / )(page 1a-53) / )(page 1a-54) / )(page 1a-55) / )(page 1a-56) / )(page 1a-57) / )(page 1a-58) / )(page 1a-58) / )(page 1a-60) / )(page 1a-61) / )(page 1a...

  • Page 143: Emission Control Devices

    Emission control devices: 1b-1 engine emission control devices precautions precautions for emission control devices b931h21200001 refer to “general precautions: in section 00”. Repair instructions crankcase breather (pcv) hose inspection b931h21206001 inspect the pcv hose in the following procedures...

  • Page 144: Engine Electrical Devices

    1c-1 engine electrical devices: engine engine electrical devices precautions precautions for engine electrical device b931h21300001 refer to “general precautions: in section 00” and “precautions for electrical circuit service: in section 00”. Component location engine electrical components location ...

  • Page 145

    Engine electrical devices: 1c-2 ckp sensor removal and installation b931h21306003 removal 1) remove the generator cover. Refer to “generator removal and installation: in section 1j”. 2) remove the ckp sensor (1) along with generator stator. Installation install the ckp sensor in the reverse order of...

  • Page 146

    1c-3 engine electrical devices: ect sensor inspection b931h21306007 refer to “dtc “c15” (p0115-h/l): ect sensor circuit malfunction: in section 1a”. Inspect the ect sensor in the following procedures: 1) remove the ect sensor. Refer to “ect sensor removal and installation (page 1c-2)”. 2) connect th...

  • Page 147

    Engine electrical devices: 1c-4 isc valve removal and installation b931h21306011 removal caution ! Be careful not to disconnect the isc valve coupler at least 3 seconds after ignition switch is turned to off. If the ecm coupler or isc valve coupler is disconnected within 3 seconds after ignition swi...

  • Page 148

    1c-5 engine electrical devices: specifications service data b931h21307001 fi sensors tightening torque specifications b931h21307002 reference: for the tightening torque of fastener not specified in this section, refer to “tightening torque list: in section 0c”. Special tools and equipment special to...

  • Page 149: Engine Mechanical

    Engine mechanical: 1d-1 engine engine mechanical schematic and routing diagram throttle cable routing diagram b931h21402001 1 1 2 1 5 5 “b” 3 6 “a” 4 i931h1140114-01 1. Throttle cable 5. Throttle cable guide 2. Brake hose 6. Clamp 3. Handlebar “a”: pass through the throttle cable inside of pin. 4. P...

  • Page 150

    1d-2 engine mechanical: diagnostic information and procedures engine mechanical symptom diagnosis b931h21404001 refer to “engine symptom diagnosis: in section 1a”. Compression pressure check b931h21404002 the compression pressure reading of a cylinder is a good indicator of its internal condition. P...

  • Page 151

    Engine mechanical: 1d-3 repair instructions engine components removable with the engine in place b931h21406001 engine components which can be removed while the engine is installed on the frame are as follows. For the installing and removing procedures, refer to respective paragraphs describing each ...

  • Page 152

    1d-4 engine mechanical: engine right side item removal inspection installation spark plug refer to “spark plug cap and spark plug removal and installation: in section 1h”. Refer to “spark plug inspection and cleaning: in section 1h”. Refer to “spark plug cap and spark plug removal and installation: ...

  • Page 153

    Engine mechanical: 1d-5 engine left side air cleaner element removal and installation b931h21406002 removal 1) remove the seat. Refer to “seat removal and installation: in section 9d”. 2) remove the air cleaner box cover. Refer to “front side exterior parts removal and installation: in section 9d”. ...

  • Page 154

    1d-6 engine mechanical: air cleaner inlet sheet construction b931h21406004 air cleaner inlet sheet removal and installation b931h21406005 refer to “air cleaner inlet sheet construction (page 1d- 6)”. Air cleaner box removal and installation b931h21406006 removal 1) remove the seat, side covers and a...

  • Page 155

    Engine mechanical: 1d-7 2) remove the air cleaner box mounting bolts (1). 3) remove the pcv hose (2) and loosen the throttle body clamp screw (3). 4) remove the air cleaner box (4). Installation install the air cleaner box in the reverse order of removal. Pay attention to the following points: • ins...

  • Page 156

    1d-8 engine mechanical: 3) remove the throttle cable as shown in the cable routing diagram. Refer to “throttle cable routing diagram (page 1d-1)”. Installation install the throttle cables in the reverse order of removal. Pay attention to the following points: • install the throttle cable as shown in...

  • Page 157

    Engine mechanical: 1d-9 throttle body construction b931h21406011 throttle body removal and installation b931h21406012 removal 1) remove the air cleaner box. Refer to “air cleaner box removal and installation (page 1d-6)”. 2) place a rug under the fuel feed hose (1) and disconnect the fuel feed hose ...

  • Page 158

    1d-10 engine mechanical: 3) disconnect the fuel injector coupler (2) and tp/iap/ iat sensor coupler (3). 4) disconnect the isc valve coupler (4). 5) remove the throttle cable cover (5). 6) disconnect the throttle cable (6). Caution ! After disconnecting the throttle cables, do not snap the throttle ...

  • Page 159

    Engine mechanical: 1d-11 • connect the throttle cable (1). • after installed throttle cable, adjust the throttle cable play. Refer to “throttle cable play inspection and adjustment: in section 0b”. Throttle body disassembly and assembly b931h21406013 refer to “throttle body removal and installation ...

  • Page 160

    1d-12 engine mechanical: caution ! • do not loosen the lock-nut (6). • the fast idle screw (7) is factory-adjusted at the time of delivery and therefore avoid removing or turning it unless otherwise necessary. Assembly assembly is the throttle body in the reverse order of removal. Pay attention to t...

  • Page 161

    Engine mechanical: 1d-13 • install the fuel delivery pipe assembly (4) to the fuel injector. Caution ! Never turn the fuel injector while installing them. • tighten the fuel delivery pipe mounting screws to the specified torque. Tightening torque fuel delivery pipe mounting screw (b): 5 n·m (0.5 kgf...

  • Page 162

    1d-14 engine mechanical: 5) remove the battery. Caution ! When disconnecting the battery lead wires, be sure to disconnect the battery (–) lead wire first. 6) remove the following parts from the vehicle. • inner fender. Refer to “front side exterior parts removal and installation: in section 9d”. • ...

  • Page 163

    Engine mechanical: 1d-15 11) remove the throttle body assembly (6). Refer to “throttle body removal and installation (page 1d- 9)”. 12) disconnect the ect sensor coupler (7). 13) remove the gearshift arm (8) and shift lever assembly (9). 14) disconnect the speed sensor coupler (10) and clamp. 15) di...

  • Page 164

    1d-16 engine mechanical: 20) remove the right footrest (19). 21) remove the rear brake pedal (20). Refer to “rear brake pedal removal and installation: in section 4a”. 22) remove the front differential mounting bolts. 23) slide the front differential assembly (21) forward. 24) remove the spring (22)...

  • Page 165

    Engine mechanical: 1d-17 engine assembly installation b931h21406016 reinstall the engine in the reverse order of engine removal. Pay attention to the following points: • tighten the engine mounting nuts (1) to the specified torque. Tightening torque engine mounting nut (a): 60 n·m (6.0 kgf-m, 43.5 l...

  • Page 166

    1d-18 engine mechanical: • after finishing the engine installation, check the following items: – throttle cable play refer to “throttle cable play inspection and adjustment: in section 0b”. – rear brake cable play refer to “rear brake pedal / rear brake (parking brake) lever inspection and adjustmen...

  • Page 167

    Engine mechanical: 1d-19 exhaust pipe remove the exhaust pipe (1). Refer to “exhaust pipe / muffler removal and installation: in section 1k”. Spark plug cap / spark plug remove the spark plug cap and spark plug. Refer to “spark plug cap and spark plug removal and installation: in section 1h”. Recoil...

  • Page 168

    1d-20 engine mechanical: 5) remove the cam chain tension adjuster (3) and gasket (4). Cylinder head cover 1) remove the valve clearance inspection caps (1) and o-rings. 2) remove the cylinder head cover (2). 3) remove the dowel pins (3) and cylinder head cover plug (4). Camshaft / crankshaft sprocke...

  • Page 169

    Engine mechanical: 1d-21 5) remove the c-ring (2) and draw out the camshaft (3) from the camshaft sprocket. Note be careful not to drop the c-ring (2) and locating pin (4) into the crankcase. 6) remove the locating pin (4) from the camshaft. 7) remove the camshaft sprocket (5). Cylinder head 1) remo...

  • Page 170

    1d-22 engine mechanical: 5) remove the dowel pins (4) and gasket (5). Cylinder 1) remove the cam chain guide (1). 2) remove the cylinder (2). Note if the cylinder does not come off easily, lightly top using a plastic hammer. 3) remove the dowel pins (3) and gasket (4). Note be careful not to drop th...

  • Page 171

    Engine mechanical: 1d-23 • install the piston and piston pin. Note when installing the piston, the indent “a” on the piston head must be faced to exhaust side. • place a clean rag over the cylinder base so as not to drop the piston pin circlips (1) into the crankcase. • install the piston pin circli...

  • Page 172

    1d-24 engine mechanical: • apply molybdenum oil solution to the sliding surface of the piston and piston rings. M/o: molybdenum oil (molybdenum oil solution) • hold each piston ring with properly position, insert the piston into the cylinder. Caution ! When installing the cylinder, pull the cam chai...

  • Page 173

    Engine mechanical: 1d-25 • tighten the cylinder head bolts (m10) to the specified two-step torque with a torque wrench sequentially and diagonally. Tightening torque cylinder head bolt (m10) (initial): 25 n·m (2.5 kgf- m, 18.0 lbf-ft) cylinder base head bolt (m10) (final): 37 n·m (3.7 kgf-m, 27.0 lb...

  • Page 174

    1d-26 engine mechanical: • align the marks “c” on the camshaft so that they are parallel with the surface of the cylinder head. • engage the hole of the camshaft sprocket with the locating pin (4) on the camshaft. Note do not rotate the crankshaft while installing the camshaft or cam chain. • instal...

  • Page 175

    Engine mechanical: 1d-27 • apply bond uniformly to the mating surface of the cylinder head cover and install it within a few minutes. Note when installing the cylinder head cover, the piston must be at the top dead center on the compression stroke. : sealant 99000–31230 (suzuki bond no.1216b or equi...

  • Page 176

    1d-28 engine mechanical: • fit a new gasket (1) and install the cam chain tension adjuster. Caution ! Use the new gasket to prevent oil leakage. • tighten the cam chain tension adjuster mounting bolts to the specified torque. Tightening torque cam chain tension adjuster mounting bolt (a): 10 n·m (1....

  • Page 177

    Engine mechanical: 1d-29 • tighten the engine mounting damper stopper bolts (3) to the specified torque. Tightening torque engine mounting damper stopper bolt (a): 23 n·m (2.3 kgf-m, 16.5 lbf-ft) valve clearance inspection and adjustment b931h21406019 refer to “valve clearance inspection and adjustm...

  • Page 178

    1d-30 engine mechanical: camshaft journal wear inspect the camshaft journal wear in the following procedures: 1) determine whether or not each journal is worn down to the limit by measuring the oil clearance with the camshaft installed in place. 2) use the plastigauge to read the clearance at the wi...

  • Page 179

    Engine mechanical: 1d-31 special tool (e): 09900–20205 (micrometer (0 – 25 mm)) camshaft journal o.D. Standard (point “c”): 17.466 – 17.484 mm (0.6876 – 0.6883 in) standard (point “d”): 21.959 – 21.980 mm (0.8645 – 0.8654 in) camshaft sprocket inspection b931h21406021 inspect the camshaft sprocket i...

  • Page 180

    1d-32 engine mechanical: cam chain tensioner inspection b931h21406024 inspect the cam chain tensioner in the following procedures: 1) remove the cam chain tensioner. Refer to “cylinder head disassembly and assembly (page 1d-38)”. 2) check the contacting surface of the cam chain tensioner. If it is w...

  • Page 181

    Engine mechanical: 1d-33 piston ring removal and installation b931h21406026 removal 1) draw out the piston pin and remove the piston. Refer to “engine top side disassembly (page 1d-18)”. 2) carefully spread the ring opening with your thumbs and then push up the opposite side of the 1st ring to remov...

  • Page 182

    1d-34 engine mechanical: 2) position the gaps of the three rings and side rails as shown. Before inserting piston into the cylinder, check that the gaps are so located. 3) install the piston and piston pin. Refer to “engine top side assembly (page 1d-22)”. Piston and piston ring inspection b931h2140...

  • Page 183

    Engine mechanical: 1d-35 special tool (b): 09900–20205 (micrometer (0 – 25 mm)) piston ring thickness standard: (1st: “c”): 0.71 – 0.76 mm (0.028 – 0.030 in) standard: (1st: “d”): 1.08 – 1.10 mm (0.0425 – 0.0433 in) standard: (2nd): 0.97 – 0.99 mm (0.038 – 0.039 in) piston ring free end gap and pist...

  • Page 184

    1d-36 engine mechanical: cylinder head cover disassembly and assembly b931h21406028 refer to “engine top side disassembly (page 1d-18)”. Refer to “engine top side assembly (page 1d-22)”. Caution ! Identify the position of each removed part. Organize the parts in their respective groups (i.E., intake...

  • Page 185

    Engine mechanical: 1d-37 3) tighten the rocker arm shaft bolts (4) to the specified torque. Caution ! Replace the gaskets with new ones. Tightening torque rocker arm shaft bolt (a): 28 n·m (2.8 kgf-m, 20 lbf-ft) cylinder head cover related parts inspection b931h21406029 refer to “cylinder head cover...

  • Page 186

    1d-38 engine mechanical: cylinder head disassembly and assembly b931h21406030 refer to “engine top side disassembly (page 1d-18)”. Refer to “engine top side assembly (page 1d-22)”. Caution ! Identify the position of each removed part. Organize the parts in their respective groups (i.E., intake, exha...

  • Page 187

    Engine mechanical: 1d-39 7) remove the oil seal (12) and valve spring seat (13). 8) remove the other valves in the same manner as described previously. Assembly assembly is in the reverse order of disassembly. Pay attention to the following points: • install the valve spring seat (1). • apply molybd...

  • Page 188

    1d-40 engine mechanical: • be sure that the rounded lip “e” of the cotter fits snugly into the groove “f” in the stem end. • install the other valves and springs in the same manner as described previously. • install the ect sensor. Refer to “ect sensor removal and installation: in section 1c”. • app...

  • Page 189

    Engine mechanical: 1d-41 • install the thermostat, thermostat cover and engine mounting dumper plate. Refer to “thermostat removal and installation: in section 1f”. • install the cam chain tensioner (5), washer (6) and cam chain tensioner bolt (7). • tighten the cam chain tensioner bolt (7) to the s...

  • Page 190

    1d-42 engine mechanical: valve face wear visually inspect each valve face for wear. Replace any valve with an abnormally worn face. The thickness of the valve face decreases as the face wears. Measure the valve head “a”. If it is out of specification replace the valve with a new one. Special tool : ...

  • Page 191

    Engine mechanical: 1d-43 valve spring the force of the coil spring keeps the valve seat tight. A weakened spring results in reduced engine power output and often accounts for the chattering noise coming from the valve mechanism. Check the valve springs for proper strength by measuring their free len...

  • Page 192

    1d-44 engine mechanical: valve seat sealing condition 1) clean and assemble the cylinder head and valve components. 2) fill the intake and exhaust ports with gasoline to check for leaks. If any leaks occur, inspect the valve seat and face for burrs or other things that could prevent the valve from s...

  • Page 193

    Engine mechanical: 1d-45 5) cool down the new valve guides in a freezer for about one hour and heat the cylinder head to 100 – 150 °c (212 – 302 °f) with a hot plate. Caution ! Do not use a burner to heat the valve guide hole to prevent cylinder head distortion. 6) apply engine oil to each valve gui...

  • Page 194

    1d-46 engine mechanical: valve seat repair b931h21406033 the valve seats (1) for both the intake and exhaust valves are machined to two different angles. The seat contact surface is cut at 45 °. Caution ! • the valve seat contact area must be inspected after each cut. • do not use lapping compound a...

  • Page 195

    Engine mechanical: 1d-47 oil filter remove the oil filter (1) with the special tool. Special tool (a): 09915–40620 (oil filter wrench) water pump remove the water pump (1). Left crankshaft spacer 1) hold the left crankshaft spacer (1) with the special tool. Special tool (a): 09930–44530 (rotor holde...

  • Page 196

    1d-48 engine mechanical: starter driven gear remove the key (1) and starter driven gear (2). Gearshift system 1) remove the gearshift shaft (1) and washers (2). 2) remove the cam driven gear (3). 3) remove the gearshift cam stopper bolt (4), gearshift cam stopper (5), washer (6) and return spring (7...

  • Page 197

    Engine mechanical: 1d-49 crank balancer driven gear 1) hold the crank balancer drive gear (1) with the special tools. 2) remove the bolt (2) and crank balancer driven gear (3). Special tool (a): 09920–53740 (clutch sleeve hub holder) (b): 09920–31020 (extension handle) oil pump 1) remove the oil pum...

  • Page 198

    1d-50 engine mechanical: 3) remove the washer (2) and crank balancer drive gear (3). 4) remove the pin (4). Automatic transmission remove the automatic transmission component parts (1). Refer to “v-belt type continuously variable automatic transmission removal and installation: in section 5a” and “c...

  • Page 199

    Engine mechanical: 1d-51 crankcase 1) remove the crankcase bolts (m6 and m8) and clamp (1). Note loosen the crankcase bolts diagonally with the smaller sizes first. 2) separate the crankcase with the special tool. Note • the crankcase separator plate is parallel with the end face of the crankcase. •...

  • Page 200

    1d-52 engine mechanical: crankshaft 1) install the removed generator cover (1) and tighten the bolts. 2) remove the crankshaft (2) with the special tool. Special tool (a): 09920–13120 (crankshaft remover) engine mount bushing remove the engine mount bushings (1) if necessary. Engine bottom side asse...

  • Page 201

    Engine mechanical: 1d-53 transfer / rear output shaft / rear output shaft bevel gear • install the rear output shaft bevel gear component parts (1) and rear output shaft (2). Refer to “rear output shaft / drive bevel gear removal and installation: in section 3d”. Note check the backlash and tooth be...

  • Page 202

    1d-54 engine mechanical: • apply grease to the oil seals and match the left and right crankcases. : grease 99000–25010 (suzuki super grease a or equivalent) • tighten the crankcase bolts to the specified torque. Note • tighten the larger diameter crankcase bolts first and then smaller ones diagonall...

  • Page 203

    Engine mechanical: 1d-55 • tighten the gear position switch mounting bolts. • clamp the lead wire firmly. Oil jet apply engine oil to the o-ring. Caution ! Use the new o-ring to prevent oil pressure leak. Automatic transmission install the automatic transmission component parts (1). Refer to “v-belt...

  • Page 204

    1d-56 engine mechanical: • lock the crank balancer drive gear nut with a center punch. Oil pump • apply thread lock to the oil pump mounting screws and tighten them. : thread lock cement 99000–32110 (thread lock cement super 1322 or equivalent) • install the washer (1) and pin (2). • install the oil...

  • Page 205

    Engine mechanical: 1d-57 • hold the crank balancer drive gear with the special tools and tighten the crank balancer driven gear bolt to the specified torque. Special tool (a): 09920–53740 (clutch sleeve hub holder) : 09920–31020 (extension handle) tightening torque crank balancer driven gear bolt (a...

  • Page 206

    1d-58 engine mechanical: • install the washers (6). • install the gearshift shaft (7). Note align the punch mark “d” of the gearshift shaft (7) with the punch mark “e” of gearshift cam stopper plate. Starter driven gear • apply engine oil to the starter driven gear bearing. • install the starter dri...

  • Page 207

    Engine mechanical: 1d-59 left crankshaft spacer • apply grease to the o-ring and lip of the oil seal. Caution ! Replace the o-ring with a new one. : grease 99000–25010 (suzuki super grease a or equivalent) • install the left crankshaft spacer. • hold the left crankshaft spacer with the special tool ...

  • Page 208

    1d-60 engine mechanical: oil filter / starter motor install a new oil filter (1) and starter motor (2). Refer to “engine oil and filter replacement: in section 0b” and “starter motor removal and installation: in section 1i”. Engine top side assemble the engine top side (1). Refer to “engine top side...

  • Page 209

    Engine mechanical: 1d-61 conrod big end side clearance check the conrod big end side clearance with the thickness gauge. If the clearance exceeds the limit, replace the crankshaft assembly and conrod with a new one. Special tool (a): 09900–20803 (thickness gauge) conrod big end side clearance servic...

  • Page 210

    1d-62 engine mechanical: bearing (crankcase and generator cover) inspection b931h21406039 refer to “engine bottom side disassembly (page 1d- 46)”. Refer to “engine bottom side assembly (page 1d-52)”. Rotate the bearing inner race by finger to inspect for abnormal play, noise and smooth rotation whil...

  • Page 211

    Engine mechanical: 1d-63 3) remove the other bearings (2) with the special tool. Special tool (b): 09913–70210 (bearing installer set (10 – 75)) right crankcase 1) remove the driveshaft spacer oil seal (1) with the special tool. Special tool (a): 09913–50121 (oil seal remover) 2) remove the snap rin...

  • Page 212

    1d-64 engine mechanical: 6) remove the each bearing (6) with the special tool. Special tool (c): 09913–70210 (bearing installer set (10 – 75)) 7) remove the front output shaft bearing (7) with the special tools. Special tool (d): 09923–74511 (bearing remover) (e): 09930–30104 (rotor remover sliding ...

  • Page 213

    Engine mechanical: 1d-65 installation caution ! The removed bearing, oil seal and snap ring must be replaced with new ones. Generator cover 1) install the oil seal (1) with suitable socket. 2) apply grease to the lip of oil seal (1). : grease 99000–25010 (suzuki super grease a or equivalent) 3) inst...

  • Page 214

    1d-66 engine mechanical: 2) apply thread lock to the bearing retainer screws and tighten them. : thread lock cement 99000–32030 (thread lock cement super 1303 or equivalent) 3) install the crankshaft oil seal no. 1 (2) with the special tool. Note the plate side of the crankshaft oil seal no. 1 (2) i...

  • Page 215

    Engine mechanical: 1d-67 left crankcase 1) install the each bearing (1) with the special tool. Note the stamped mark side of the bearing faces inside of crankcase. Special tool (a): 09913–70210 (bearing installer set (10 – 75)) 2) apply thread lock to the bearing retainer screws and tighten them. : ...

  • Page 216

    1d-68 engine mechanical: camshaft + cylinder head unit: mm (in) cylinder + piston + piston ring unit: mm (in) conrod + crankshaft unit: mm (in) item standard limit cam height in. 33.45 – 33.50 (1.317 – 1.319) 33.15 (1.305) ex. 33.47 – 33.52 (1.318 – 1.320) 33.17 (1.306) camshaft journal oil clearanc...

  • Page 217

    Engine mechanical: 1d-69 tightening torque specifications b931h21407002 note the specified tightening torque is described in the following. “air cleaner inlet sheet construction (page 1d-6)” “throttle body components (page 1d-8)” reference: for the tightening torque of fastener not specified in this...

  • Page 218

    1d-70 engine mechanical: special tools and equipment recommended service material b931h21408001 note required service material is also described in the following. “throttle body components (page 1d-8)” special tool b931h21408002 material suzuki recommended product or specification note grease suzuki...

  • Page 219

    Engine mechanical: 1d-71 09900–20204 09900–20205 micrometer (75 – 100 mm) micrometer (0 – 25 mm) )(page 1d-34) )(page 1d-31) / )(page 1d-35) / )(page 1d-35) / )(page 1d-37) / )(page 1d-42) 09900–20530 09900–20602 cylinder gauge set dial gauge )(page 1d-32) )(page 1d-30) / )(page 1d-35) 09900–20605 0...

  • Page 220

    1d-72 engine mechanical: 09913–10750 09913–50121 compression gauge adapter oil seal remover )(page 1d-2) )(page 1d-63) / )(page 1d-63) / )(page 1d-64) / )(page 1d-64) 09913–70210 09915–40620 bearing installer set (10 – 75) oil filter wrench )(page 1d-66) / )(page 1d-66) / )(page 1d-67) / )(page 1d-6...

  • Page 221

    Engine mechanical: 1d-73 09920–13120 09920–31020 crankshaft remover extension handle )(page 1d-51) / )(page 1d-52) )(page 1d-49) / )(page 1d-49) / )(page 1d-55) / )(page 1d-57) 09920–53740 09921–20240 clutch sleeve hub holder bearing remover set )(page 1d-49) / )(page 1d-49) / )(page 1d-55) / )(page...

  • Page 222: Engine Lubrication System

    1e-1 engine lubrication system: engine engine lubrication system precautions precautions for engine oil b931h21500001 refer to “fuel and oil recommendation: in section 0a”. Schematic and routing diagram engine lubrication system chart diagram b931h21502001 oil sump filter oil pump relief valve oil f...

  • Page 223

    Engine lubrication system: 1e-2 engine lubrication circuit diagram b931h21502002 to cylinder head oil pump i931h1150002-03.

  • Page 224

    1e-3 engine lubrication system: exhaust side intake side i931h1150003-02.

  • Page 225

    Engine lubrication system: 1e-4 diagnostic information and procedures engine lubrication symptom diagnosis b931h21504001 oil pressure check b931h21504002 check the engine oil pressure periodically. This will give a good indication of the condition of the moving parts. Note before checking the oil pr...

  • Page 226

    1e-5 engine lubrication system: 8) stop the engine and remove the oil pressure gauge and attachment. 9) reinstall the main oil gallery plug (1) and tighten it to the specified torque. Caution ! Use a new gasket to prevent oil leakage. Tightening torque main oil gallery plug (a): 18 n·m (1.8 kgf-m, 1...

  • Page 227

    Engine lubrication system: 1e-6 oil sump filter inspection and cleaning b931h21506004 inspect the oil sump filter in the following procedures: 1) remove the oil sump filter. Refer to “oil sump filter removal and installation (page 1e-5)”. 2) if the oil sump filter is clogged with sediment or rust, c...

  • Page 228

    1e-7 engine lubrication system: oil pump construction b931h21506006 oil jet inspection b931h21506007 refer to “oil jet removal and installation (page 1e-6)”. Make sure that the oil jet is not clogged. If it is clogged, clean the oil passage using a wire of the proper size and compressed air. Oil pum...

  • Page 229

    Engine lubrication system: 1e-8 4) install the left crankshaft spacer (5). 5) hold the crankshaft spacer (5) and remove the crank balancer driven gear bolt and washer. 6) remove the snap ring (6) and oil pump driven gear (7). Special tool : 09900–06107 (snap ring remover (open type)) 7) remove the p...

  • Page 230

    1e-9 engine lubrication system: • install the crank balancer driven gear (3). Note align the punch mark “a” of crank balancer drive gear with the punch marks “b” of each crank balancer driven gear as shown. • apply thread lock super to the oil pump driven gear bolt (4). : thread lock cement 99000–32...

  • Page 231

    Engine lubrication system: 1e-10 specifications service data b931h21507001 oil pump oil tightening torque specifications b931h21507002 note the specified tightening torque is described in the following. “oil pump construction (page 1e-7)” reference: for the tightening torque of fastener not specifie...

  • Page 232

    1e-11 engine lubrication system: special tool b931h21508002 09900–06107 09900–26006 snap ring remover (open type) engine tachometer )(page 1e-8) / )(page 1e- 8) )(page 1e-4) 09915–74511 09915–74533 oil pressure gauge (600 kpa) oil pressure gauge adapter )(page 1e-4) )(page 1e-4).

  • Page 233: Engine Cooling System

    Engine cooling system: 1f-1 engine engine cooling system precautions precautions for engine cooling system b931h21600001 warning ! • you can be injured by boiling fluid or steam if you open the radiator cap when the engine is hot. After the engine cools, wrap a thick cloth around cap and carefully r...

  • Page 234

    1f-2 engine cooling system: general description engine coolant description b931h21601001 caution ! • use a high quality ethylene glycol base anti-freeze, mixed with distilled water. Do not mix an alcohol base anti-freeze and different brands of anti-freeze. • do not put in more than 60% anti-freeze ...

  • Page 235

    Engine cooling system: 1f-3 water hose routing diagram b931h21602002 1 2 3 4 5 “ d ” 5 6 7 “c” “a” “b” “a” (a) (b) “b” i931h1160057-01 1. Thermostat 6. Radiator outlet hose “d”: face the tip of the clip to upper. 2. Radiator 7. Water pump : 17 n ⋅m (1.7 kgf-m, 12.5 lbf-ft) 3. Reservoir tank “a”: yel...

  • Page 236

    1f-4 engine cooling system: diagnostic information and procedures engine cooling symptom diagnosis b931h21604001 repair instructions cooling circuit inspection b931h21606001 warning ! • do not open the radiator cap when the engine is hot, as you may be injured by escaping hot liquid or vapor. • when...

  • Page 237

    Engine cooling system: 1f-5 radiator cap inspection b931h21606002 inspect the radiator cap in the following procedures: 1) remove the radiator cap. Refer to “cooling circuit inspection (page 1f-4)”. 2) attach the radiator cap (1) to the radiator tester (2) as shown in the figure. 3) slowly apply pre...

  • Page 238

    1f-6 engine cooling system: 6) disconnect the cooling fan thermo-switch coupler (6) and cooling fan motor coupler (7). 7) remove the radiator (8). 8) remove the radiator cover (9). 9) remove the cooling fan assembly (10). 10) remove the cooling fan thermo-switch (11). Installation install the coolin...

  • Page 239

    Engine cooling system: 1f-7 cooling fan inspection b931h21606006 inspect the cooling fan in the following procedures: 1) disconnect the cooling fan motor coupler (1). 2) test the cooling fan motor for load current with an ammeter connected as shown in the figure. If the fan motor does not turn, repl...

  • Page 240

    1f-8 engine cooling system: radiator reservoir tank inspection b931h21606008 inspect the radiator reservoir tank coolant leaks. If any defects are found, replace the radiator reservoir tank with a new one. Water hose inspection b931h21606009 inspect the water hoses in the following procedures: 1) re...

  • Page 241

    Engine cooling system: 1f-9 installation install the cooling fan thermo-switch in the reverse order of removal. Pay attention to the following points: • apply engine coolant to the o-ring. Caution ! Replace the removed o-ring with a new one. • tighten the cooling fan thermo-switch (1) to the specifi...

  • Page 242

    1f-10 engine cooling system: thermostat removal and installation b931h21606014 removal 1) drain a small amount of engine coolant. Refer to “cooling system inspection: in section 0b”. 2) move the gearshift-rod (1) by removing the gearshift arm. Refer to “shift lever assembly removal and installation:...

  • Page 243

    Engine cooling system: 1f-11 thermostat inspection b931h21606015 inspect the thermostat in the following procedures: 1) remove the thermostat. Refer to “thermostat removal and installation (page 1f-10)”. 2) inspect the thermostat pellet for signs of cracking. 3) test the thermostat at the bench for ...

  • Page 244

    1f-12 engine cooling system: water pump components b931h21606016 water pump removal and installation b931h21606017 removal note before draining engine oil and engine coolant, inspect engine oil and coolant leakage between the water pump and crankcase. If engine oil is leaking, visually inspect the o...

  • Page 245

    Engine cooling system: 1f-13 4) disconnect the outlet hose (1) and water bypass hose (2). 5) remove the water pump assembly (3). Installation install the water pump in the reverse order of removal. Pay attention to the following points: • apply grease to the o-rings. Caution ! Replace the o-rings wi...

  • Page 246

    1f-14 engine cooling system: 3) remove the o-ring (3). 4) remove the e-ring (4) and cap (5). 5) remove the pin (6) and washer (7). 6) remove the impeller (8). 7) remove the mechanical seal ring (9) and rubber seal (10) from the impeller. 8) remove the mechanical seal with the special tool. Note if t...

  • Page 247

    Engine cooling system: 1f-15 assembly 1) install the oil seal with the special tool. Caution ! Replace the oil seal with a new one. Note the stamped mark on the oil seal should face mechanical seal side. Special tool (a): 09913–70210 (bearing installer set (10 – 75)) 2) apply a small quantity of the...

  • Page 248

    1f-16 engine cooling system: 6) apply silicone grease to the mechanical seal ring (2). : grease 99000–25100 (suzuki silicone grease or equivalent) 7) apply molybdenum solution to the impeller shaft. M/o: molybdenum oil (molybdenum oil solution) 8) install the impeller shaft to the water pump body. 9...

  • Page 249

    Engine cooling system: 1f-17 water pump related parts inspection b931h21606019 refer to “water pump disassembly and assembly (page 1f-13)”. Mechanical seal visually inspect the mechanical seal for damage, with particular attention given to the sealing face. Replace the mechanical seal that shows ind...

  • Page 250

    1f-18 engine cooling system: specifications service data b931h21607001 thermostat + radiator + fan + coolant tightening torque specifications b931h21607002 note the specified tightening torque is described in the following. “water hose routing diagram (page 1f-3)” “water pump components (page 1f-12)...

  • Page 251

    Engine cooling system: 1f-19 special tools and equipment recommended service material b931h21608001 note required service material is also described in the following. “water pump components (page 1f-12)” special tool b931h21608002 material suzuki recommended product or specification note grease suzu...

  • Page 252: Fuel System

    1g-1 fuel system: engine fuel system precautions precautions for fuel system b931h21700001 warning ! • keep away from fire or spark. • during disassembling, use care to minimize spillage of gasoline. • spilled gasoline should be wiped off immediately. • work in a well-ventilated area. Caution ! • to...

  • Page 253

    Fuel system: 1g-2 general description fuel system description b931h21701001 fuel system the fuel delivery system consists of the fuel tank (1), fuel pump (2), fuel mesh filter (3), fuel feed hose (4), fuel delivery pipe (5) (including fuel injector) and fuel pressure regulator (6). There is no fuel ...

  • Page 254

    1g-3 fuel system: schematic and routing diagram fuel hose routing diagram b931h21702001 2 2 1 1 3 1 3 fr lh rh rr lh rh fr rr 4 i931h1170028-01 1. Fuel hose 3. Pcv hose 2. Air cleaner box 4. Pass the fuel hose between the air cleaner guide..

  • Page 255

    Fuel system: 1g-4 fuel tank breather hose routing diagram b931h21702002 1 3 2 7 2 3 5 6 4 1 2 6 8 (a) “a” i831g1170003-04 1. Frame 5. Valve (black) “a”: align the fuel pump nipple with the mark. 2. Fuel tank breather hose 6. Valve (orange) : 35 n ⋅m (3.5 kgf-m, 25.5 lbf-ft) 3. Check valve hose 7. Ma...

  • Page 256

    1g-5 fuel system: diagnostic information and procedures fuel system diagnosis b931h21704001 condition possible cause correction / reference item engine will not start or is hard to start (no fuel reaching the intake manifold) clogged fuel filter or fuel hose. Clean or replace. Defective fuel pump. R...

  • Page 257

    Fuel system: 1g-6 repair instructions fuel pressure inspection b931h21706001 warning ! • keep away from fire or spark. • spilled gasoline should be wiped off immediately. • work in a well-ventilated area. Inspect the fuel pressure in the following procedures: 1) remove the seat. Refer to “seat remov...

  • Page 258

    1g-7 fuel system: 2) place a rag under the fuel feed hose (1) and disconnect fuel feed hose from the fuel pump. 3) place the measuring cylinder and insert the fuel feed hose end into the measuring cylinder. 4) disconnect the fuel pump lead wire coupler (2). 5) connect a proper lead wire into the fue...

  • Page 259

    Fuel system: 1g-8 fuel hose inspection b931h21706005 refer to “fuel line inspection: in section 0b”. Fuel feed hose removal and installation b931h21706006 removal 1) remove the rear fender. Refer to “rear side exterior parts removal and installation: in section 9d”. 2) disconnect the fuel feed hose ...

  • Page 260

    1g-9 fuel system: fuel pump components b931h21706010 fuel pump assembly removal and installation b931h21706011 removal warning ! • spilled gasoline should be wiped off immediately. • keep away from fire or spark. • work in a well-ventilated area. 1) remove the fuel tank. Refer to “fuel tank removal ...

  • Page 261

    Fuel system: 1g-10 fuel pump disassembly and assembly b931h21706012 refer to “fuel pump assembly removal and installation (page 1g-9)”. Disassembly remove the fuel cup holder (1) with a (–) screw driver. Assembly assemble the fuel tank pump in the reverse order of the disassembly. Fuel mesh filter i...

  • Page 262

    1g-11 fuel system: 3) place a rug under the fuel feed hose (1) and disconnect the fuel feed hose (1) from the fuel delivery pipe. 4) disconnect the injector coupler (2). 5) remove the fuel delivery pipe (3) with the injector (4). 6) remove the fuel injector (4) from the fuel delivery pipe. Installat...

  • Page 263

    Fuel system: 1g-12 fuel tank pressure control (ftpc) valve removal and installation b931h21706016 removal 1) remove the rear carrier. Refer to “rear carrier removal and installation: in section 9e”. 2) remove the seat. Refer to “seat removal and installation: in section 9d”. 3) remove the side cover...

  • Page 264

    1g-13 fuel system: fuel tank pressure control (ftpc) valve inspection b931h21706017 inspect the ftpc valve in the following procedures: 1) remove the ftpc valve. Refer to “fuel tank pressure control (ftpc) valve removal and installation (page 1g-12)”. 2) check the ftpc valve if air can pass through ...

  • Page 265

    Fuel system: 1g-14 special tools and equipment special tool b931h21708001 09900–25008 09915–74521 multi circuit tester set adapter hose )(page 1g-7) )(page 1g-6) 09915–77331 09940–40211 oil pressure gauge (1000 kpa) fuel pressure gauge adapter )(page 1g-6) )(page 1g-6) 09940–40220 09941–51012 fuel p...

  • Page 266: Ignition System

    1h-1 ignition system: engine ignition system general description override switch description b931h21801001 the override switch allows the rider to increase the power available by overriding the normal speed limiter in forward differential lock or reverse. For example, the rider may need to use extra...

  • Page 267

    Ignition system: 1h-2 diagnostic information and procedures ignition system symptom diagnosis b931h21804001 no spark or poor spark b931h21804002 troubleshooting note • check that the transfer is in neutral and the engine stop switch is in the “run” position. Check that the fuse is not blown and the ...

  • Page 268

    1h-3 ignition system: repair instructions spark plug cap and spark plug removal and installation b931h21806001 removal warning ! The hot engine can burn you. Wait until the engine is cool enough to touch. 1) turn the ignition switch off. 2) remove the right side cover and right inner fender. Refer t...

  • Page 269

    Ignition system: 1h-4 ignition coil and plug cap inspection b931h21806003 refer to “electrical components location: in section 0a”. Ignition coil primary peak voltage 1) remove the right side cover and right inner fender. Refer to “front side exterior parts removal and installation: in section 9d”. ...

  • Page 270

    1h-5 ignition system: ignition coil resistance 1) disconnect the spark plug cap. Refer to “ignition coil and plug cap inspection (page 1h-4)”. 2) disconnect the ignition coil lead wire. 3) measure the ignition coil resistance in both the primary and secondary coils. If the resistance is not within t...

  • Page 271

    Ignition system: 1h-6 4) measure the ckp sensor peak voltage in the following procedures: a) shift the transfer to the neutral, turn the ignition switch on. B) press the starter button and allow the engine to crank for a few seconds, and then measure the ckp sensor peak voltage. 5) repeat the b) pro...

  • Page 272

    1h-7 ignition system: 5) after finishing the engine stop switch inspection, reinstall the removed parts. Ignition switch inspection b931h21806008 refer to “ignition switch inspection: in section 9c”. Ignition switch removal and installation b931h21806009 removal 1) remove the left inner fender. Refe...

  • Page 273

    Ignition system: 1h-8 emergency switch inspection (for p-17) b931h21806011 inspect the emergency switch for continuity with a tester. If any abnormality is found, replace the emergency switch assembly with a new one. Refer to “wiring harness routing diagram: in section 9a”. Special tool : 09900–2500...

  • Page 274: Starting System

    1i-1 starting system: engine starting system schematic and routing diagram starting system diagram b931h21902001 refer to “wire color symbols: in section 0a”. Component location starting system components location b931h21903001 refer to “electrical components location: in section 0a”. Diagnostic inf...

  • Page 275

    Starting system: 1i-2 starter motor will not run b931h21904002 note make sure the fuses are not blown and the battery is fully-charged before diagnosing. Troubleshooting starter motor runs but does not crank the engine b931h21904003 the starter motor runs when the transfer is in neutral, but does no...

  • Page 276

    1i-3 starting system: repair instructions starter motor components b931h21906001 starter motor removal and installation b931h21906002 removal 1) turn the ignition switch off and disconnect the battery (–) lead wire. Refer to “battery removal and installation: in section 1j”. 2) remove the right side...

  • Page 277

    Starting system: 1i-4 4) remove the starter motor. Installation install the starter motor in the reverse order of removal. Pay attention to the following points: • apply grease to the starter motor o-ring. : grease 99000–25010 (suzuki super grease a or equivalent) caution ! Replace the o-ring with a...

  • Page 278

    1i-5 starting system: • apply a small quantity of moly paste to the armature shaft. : moly paste 99000–25140 (suzuki moly paste or equivalent) • align the match mark on the starter motor case with the match mark on the housing end. Note the groove side “a” of brush holder the housing end. • tighten ...

  • Page 279

    Starting system: 1i-6 armature coil measure for continuity between each segment. Measure for continuity between each segment and the armature shaft. If there is no continuity between the segments or there is continuity between the segments and shaft, replace the armature with a new one. Special tool...

  • Page 280

    1i-7 starting system: starter relay inspection b931h21906006 inspect the starter relay in the following procedures: 1) remove the starter relay. Refer to “starter relay removal and installation (page 1i-6)”. 2) apply 12 v to “a” and “b” terminals and check for continuity between the positive and neg...

  • Page 281

    Starting system: 1i-8 neutral relay inspection b931h21906008 inspect the neutral relay in the following procedures: 1) remove the neutral relay. Refer to “neutral relay removal and installation (page 1i-7)”. 2) check the insulation between “a” and “b” terminals using the multi-circuit tester. 3) app...

  • Page 282

    1i-9 starting system: parking brake relay inspection b931h21906011 inspect the parking brake relay in the following procedures: 1) remove the parking brake relay. Refer to “parking brake relay removal and installation (page 1i-8)”. 2) check the insulation between “a” and “b” terminals using the mult...

  • Page 283

    Starting system: 1i-10 4) after finishing the gear position switch inspection, reinstall the removed parts. Starter idle gear / starter clutch removal and installation b931h21906014 removal 1) drain engine oil. Refer to “engine oil and filter replacement: in section 0b”. 2) remove the generator cove...

  • Page 284

    1i-11 starting system: installation install the starter clutch in the reverse order of removal. Pay attention to the following points: • when inserting the one way clutch (1) into the guide (2), fit the flange “a” in the step of the guide (2). Note be sure to seat the flange “a” of the one way clutc...

  • Page 285

    Starting system: 1i-12 starter driven gear bearing removal and installation b931h21906015 removal 1) remove the starter driven gear. Refer to “starter idle gear / starter clutch removal and installation (page 1i-10)”. 2) remove the bearing with the special tool. Special tool (a): 09913–70210 (bearin...

  • Page 286

    1i-13 starting system: starter idle gear inspect the starter idle gear no. 1 (1) and no. 2 (2) for wear or damage. If any damage is found, replace it with a new one. Starter button inspection b931h21906017 inspect the starter button in the following procedures: 1) remove the left inner fender. Refer...

  • Page 287

    Starting system: 1i-14 tightening torque specifications b931h21907002 note the specified tightening torque is described in the following. “starter motor components (page 1i-3)” reference: for the tightening torque of fastener not specified in this section, refer to “tightening torque list: in sectio...

  • Page 288: Charging System

    1j-1 charging system: engine charging system schematic and routing diagram charging system diagram b931h21a02001 component location charging system components location b931h21a03001 refer to “electrical components location: in section 0a”. Diagnostic information and procedures charging system sympto...

  • Page 289

    Charging system: 1j-2 battery runs down quickly b931h21a04002 troubleshooting battery overcharges faulty regulator/rectifier. Replace. Faulty battery. Replace. Poor contact of generator lead wire coupler. Repair. Battery runs down quickly trouble in charging system. Check the generator, regulator/re...

  • Page 290

    1j-3 charging system: repair instructions battery current leakage inspection b931h21a06001 inspect the battery current leakage in the following procedures: 1) turn the ignition switch off. 2) remove the seat. Refer to “seat removal and installation: in section 9d”. 3) disconnect the (–) battery lead...

  • Page 291

    Charging system: 1j-4 3) measure the resistance between the three lead wires. If the resistance is out of specified value, replace the stator with a new one. Also, check that the generator core is insulated properly. Note when making this test, it is not necessary to remove the generator. Special to...

  • Page 292

    1j-5 charging system: 7) disconnect the gearshift lever arm (1) and speed sensor coupler (2). 8) remove the recoil cover (3). 9) disconnect the ckp sensor coupler (4) and generator coupler (5) and remove the clamp (6). 10) hold the left crankshaft spacer (7) with the special tool. Special tool (a): ...

  • Page 293

    Charging system: 1j-6 16) remove the generator rotor assembly (11) with the special tool. Note remove the starter clutch if necessary. Refer to “starter idle gear / starter clutch removal and installation: in section 1i”. Special tool (c): 09930–30721 (rotor remover) 17) remove the key (12). 18) rem...

  • Page 294

    1j-7 charging system: • hold the generator rotor and tighten the generator rotor nut (3) to the specified torque. Tightening torque generator rotor nut (d): 140 n·m (14.0 kgf-m, 101.5 lbf-ft) • install the dowel pins and new gasket (4). Caution ! Use a new gasket (4) to prevent oil leakage. • instal...

  • Page 295

    Charging system: 1j-8 regulator / rectifier inspection b931h21a06005 inspect the regulator/rectifier in the following procedures: 1) turn the ignition switch off. 2) remove the rear fender. Refer to “rear side exterior parts removal and installation: in section 9d”. 3) disconnect the regulator/recti...

  • Page 296

    1j-9 charging system: battery components b931h21a06006 battery charging b931h21a06007 initial charging filling electrolyte note when filling electrolyte, the battery must be removed from the vehicle and must be put on the level ground. 1) remove the aluminum tape (1) which seals the battery filler h...

  • Page 297

    Charging system: 1j-10 note if no air bubbles come out from a filler port, tap the bottom of the electrolyte container two or three times. Never remove the container from the battery. 6) after confirming that the electrolyte has entered the battery completely, remove the electrolyte containers from ...

  • Page 298

    1j-11 charging system: battery recharging caution ! Do not remove the caps on the battery top while recharging. Note when the vehicle is not used for a long period, check the battery every 1 month to prevent the battery discharge. 1) remove the battery from the vehicle. Refer to “battery removal and...

  • Page 299

    Charging system: 1j-12 installation install the battery in the reverse order of removal. Pay attention to the following point: caution ! Never use anything except the specified battery. • tighten the battery lead wire mounting bolts securely. • apply thread lock to the battery stay mounting bolts an...

  • Page 300

    1j-13 charging system: tightening torque specifications b931h21a07002 reference: for the tightening torque of fastener not specified in this section, refer to “tightening torque list: in section 0c”. Special tools and equipment recommended service material b931h21a08001 special tool b931h21a08002 fa...

  • Page 301: Exhaust System

    Exhaust system: 1k-1 engine exhaust system precautions precautions for exhaust system b931h21b00001 warning ! To avoid the risk of being burned, do not touch the exhaust system when the system is hot. Any service on the exhaust system should be performed when the system is cool. Caution ! Make sure ...

  • Page 302

    1k-2 exhaust system: exhaust pipe / muffler removal and installation b931h21b06002 removal 1) remove the inner fenders and side covers, left and right. Refer to “front side exterior parts removal and installation: in section 9d”. 2) remove the rear carrier. Refer to “rear carrier removal and install...

  • Page 303

    Exhaust system: 1k-3 • install the exhaust pipe gasket (2) and connector (3). Caution ! Replace the gasket and connector with new ones. • tighten the exhaust pipe nuts (4) and muffler connecting mounting bolt (5) to the specified torque. Tightening torque exhaust pipe nut (b): 23 n·m (2.3 kgf-m, 16....

  • Page 304

    1k-4 exhaust system:.

  • Page 305: Section 2

    Table of contents 2- i 2 section 2 contents suspension precautions .................................................2-1 precautions............................................................. 2-1 precautions for suspension .................................. 2-1 suspension general diagnosis............

  • Page 306: Precautions

    2-1 precautions: suspension precautions precautions precautions for suspension b931h22000001 refer to “general precautions: in section 00”. Warning ! All suspensions, bolts and nuts are an important part in that it could affect the performance of vital parts. They must be tightened to the specified ...

  • Page 307: Suspension General Diagnosis

    Suspension general diagnosis: 2a-1 suspension suspension general diagnosis diagnostic information and procedures suspension and wheel symptom diagnosis b931h22104001 condition possible cause correction / reference item wobbly front wheel distorted wheel rim. Replace. Worn hub bearings. Replace. Defe...

  • Page 308: Front Suspension

    2b-1 front suspension: suspension front suspension repair instructions front suspension components b931h22206001 (a) 1 2 (b) 9 16 13 15 14 18 (d) 13 17 fwd fwd 19 19 19 (b) 3 (d) (d) 4 7 6 6 7 8 (c) 11 (c) 11 10 12 5 i931h1220054-02 1. Front shock absorber mounting bolt 10. Suspension arm pivot bolt...

  • Page 309

    Front suspension: 2b-2 front suspension assembly construction b931h22206002 “ a ” “ a ” 10 11 (e) 7 8 (d) 6 (c) 4 (b) 2 (a) 1 11 9 (d) 5 (d) 6 (b) 3 i931h1220055-01 1. Front shock absorber mounting bolt 11. Inner dust seal : align the surface of dust seal with the edge of suspension arm. 2. Front sh...

  • Page 310

    2b-3 front suspension: front shock absorber removal and installation b931h22206003 caution ! Make sure that the vehicle is supported securely. Removal 1) remove the front wheel. Refer to “front / rear wheel removal and installation: in section 2d”. 2) remove the front shock absorber upper mounting b...

  • Page 311

    Front suspension: 2b-4 3) install the front shock absorber. Refer to “front shock absorber removal and installation (page 2b- 3)”. Spring pre-load adjustment b931h22206006 warning ! Be sure to adjust the spring pre-load on the both suspensions equally. • turn the spring tension ring (1) to the desir...

  • Page 312

    2b-5 front suspension: 8) disengage the tie-rod end (8) with the special tool. Warning ! When using the tie-rod end remover, keep clear of the tie-rod end because it may come loose with some force and could strike you. Special tool (a): 09942–72410 (tie-rod end remover) 9) remove the cotter pins, kn...

  • Page 313

    Front suspension: 2b-6 • install the cotter pins (3). Caution ! The removed cotter pins (3) must be replaced with new ones. • clean up the tie-rod end and the mating surface of the steering knuckle. Note make surfaces free from moisture, oil, dust and other foreign materials. • connect the tie-rod e...

  • Page 314

    2b-7 front suspension: • install the wheel hub (10), washer (11) and front hub nut (12). Note the conical side of washer (11) faces out side. Refer to “front suspension assembly construction (page 2b-2)”. • install the brake caliper. Refer to “front brake caliper removal and installation: in section...

  • Page 315

    Front suspension: 2b-8 3) remove the inner dust seal (3) with the special tool. Special tool (a): 09913–50121 (oil seal remover) 4) remove the wheel hub bearing (4), using the hydraulic press and special tool. Special tool (b): 09913–70210 (bearing installer set (10 – 75)) installation install the w...

  • Page 316

    2b-9 front suspension: • install a new outer dust seal (4) using a suitable size socket wrench. Caution ! Replace the outer dust seal (4) with a new one. • apply grease to the lip of outer dust seal (4). : grease 99000–25160 (water resistance grease or equivalent) front suspension upper / lower arm ...

  • Page 317

    Front suspension: 2b-10 3) set the steering knuckle (3) and install the suspension upper arm (4). 4) tighten the suspension upper arm pivot nut (5) and shock absorber mounting nut (6). 5) tighten the steering knuckle end nut and tie-rod end nut, and then install the wheel hub. Refer to “front wheel ...

  • Page 318

    2b-11 front suspension: steering knuckle end removal and installation b931h22206012 refer to “front wheel hub / steering knuckle removal and installation (page 2b-4)” and “front suspension upper / lower arm removal and installation (page 2b- 9)”. Removal upper • remove the snap ring (1) with the spe...

  • Page 319

    Front suspension: 2b-12 • install the snap ring (2) with the special tool. Caution ! Replace the snap ring (2) with a new one. Special tool : 09900–06107 (snap ring remover (open type)) lower • install the knuckle end (1) with the special tool. Special tool (a): 09913–70210 (bearing installer set (1...

  • Page 320

    2b-13 front suspension: lower arm inspect the front lower arm (1) and bushings (2) for bend or damage. If any defects are found, replace the defective parts with new ones. Refer to “front suspension lower arm bushing removal and installation (page 2b-14)”. Front suspension upper arm bushing and inne...

  • Page 321

    Front suspension: 2b-14 2) apply grease to the lip of inner dust seals, spacer (1) and inside of dust seals (2). : grease 99000–25160 (water resistance grease or equivalent) 3) install the washers (3) to the dust seals (2) and install the spacer (1) and dust seals (2) to the front suspension upper a...

  • Page 322

    2b-15 front suspension: specifications service data b931h22207001 suspension tightening torque specifications b931h22207002 note the specified tightening torque is described in the following. “front suspension components (page 2b-1)” “front suspension assembly construction (page 2b-2)” reference: fo...

  • Page 323

    Front suspension: 2b-16 special tool b931h22208002 09900–06107 09900–06108 snap ring remover (open type) snap ring remover (close type) )(page 2b-11) / )(page 2b-11) / )(page 2b-12) / )(page 2b-12) )(page 2b-7) / )(page 2b- 8) 09913–50121 09913–70210 oil seal remover bearing installer set (10 – 75) ...

  • Page 324: Rear Suspension

    2c-1 rear suspension: suspension rear suspension repair instructions rear suspension components b931h22306001 7 6 8 (a) 16 14 (a) 18 2 4 3 7 (a) 15 1 (a) 16 9 (a) 18 (a) 17 (a) 15 12 10 13 11 5 fwd fwd 7 7 8 9 14 7 8 8 8 9 8 9 8 8 8 (a) 17 7 (a) 16 i931h1230056-06 1. Rear shock absorber 9. Spacer 17...

  • Page 325

    Rear suspension: 2c-2 rear suspension assembly construction b931h22306002 9 9 5 (a) 1 “ a ” “ a ” 6 5 “ a ” 7 6 5 7 5 7 7 (a) 2 (b) 3 3 8 4 “ a ” 5 6 7 5 7 7 (a) 2 i931h1230060-04 1. Rear suspension arm pivot nut (upper) 8. Rear hub bearing 2. Rear suspension arm pivot nut (lower) “a”: 6.8 – 7.2 mm ...

  • Page 326

    2c-3 rear suspension: rear shock absorber removal and installation b931h22306003 removal 1) place the vehicle on level ground and support the vehicle with a jack. 2) remove the rear wheel assembly. Refer to “front / rear wheel removal and installation: in section 2d”. 3) remove the rear drive shaft ...

  • Page 327

    Rear suspension: 2c-4 4) remove the shock absorber (2) by removing the shock absorber upper and lower mounting bolt and nut. Installation install the rear shock absorber in the reverse order of removal. Pay attention to the following points: • apply thread lock to the rear shock absorber mounting bo...

  • Page 328

    2c-5 rear suspension: rear wheel hub / suspension knuckle removal and installation b931h22306007 note the right and left suspension parts are installed procedure for one side is the same as that for the other side. Removal 1) remove the cotter pin (1) and loosen the hub nut (2). 2) remove the rear w...

  • Page 329

    Rear suspension: 2c-6 • tighten the rear knuckle nuts (3) to the specified torque. Tightening torque rear suspension knuckle nut (upper and lower) (a): 60 n·m (6.0 kgf-m, 43.5 lbf-ft) • install the washer (4) and hub nut (5). Note the conical side of washer (4) faces outside. Refer to “rear suspensi...

  • Page 330

    2c-7 rear suspension: 2) remove the snap ring (2) with the special tool. Special tool : 09900–06108 (snap ring remover (close type)) 3) remove the inner dust seal (3) with the special tool. Special tool (a): 09913–50121 (oil seal remover) 4) remove the hub bearing (4) using the hydraulic press and s...

  • Page 331

    Rear suspension: 2c-8 • install the snap ring (2) with the special tool. Caution ! Never reuse snap ring (2). Special tool : 09900–06108 (snap ring remover (close type)) • install a new inner dust seal (3) using a suitable size socket wrench. Caution ! Replace the inner dust seal (3) with a new one....

  • Page 332

    2c-9 rear suspension: 5) disconnect the stabilizer joint (3) from the rear suspension lower arm (4). 6) remove the shock absorber mounting lower bolt (5) and nut (6). 7) remove the rear suspension lower arm (4). Installation install the suspension arms in the reverse order of removal. Pay attention ...

  • Page 333

    Rear suspension: 2c-10 • keep a vehicle on a level ground. Next loosen each pivot nut and tighten them to the specified torque again. Tightening torque suspension arm lower pivot nut: 60 n·m (6.0 kgf- m, 43.5 lbf-ft) suspension arm upper pivot nut: 60 n·m (6.0 kgf- m, 43.5 lbf-ft) rear suspension ar...

  • Page 334

    2c-11 rear suspension: suspension knuckle 1) inspect the following parts for wear or damage. If any defects are found, replace defective parts with new ones. • suspension knuckle (1) • dust seal (2) • washer (3) • spacer (4) 2) insert the spacer into bushings. 3) check the play by moving the spacer ...

  • Page 335

    Rear suspension: 2c-12 installation 1) install the rear suspension upper arm bushings (1) and inner dust seals (2) with the special tool and suitable socket wrench. Note position the bushings and dust seals by referring to “rear suspension assembly construction (page 2c-2)”. Caution ! The removed bu...

  • Page 336

    2c-13 rear suspension: 2) remove the rear suspension lower arm bushings (4) along with the inner dust seals (5) with the special tools. Special tool : 09923–73210 (bearing remover) : 09930–30104 (rotor remover slide shaft) 3) remove the another inner dust seal (6) with the special tool. Special tool...

  • Page 337

    Rear suspension: 2c-14 rear suspension knuckle bushing and inner dust seal removal and installation b931h22306014 refer to “rear wheel hub / suspension knuckle removal and installation (page 2c-5)”. Removal 1) remove the following parts from the suspension knuckle. • dust seal (1) • washer (2) • spa...

  • Page 338

    2c-15 rear suspension: 2) apply grease to the lip of the inner dust seals, spacer (1) and inside of dust seals (2). : grease 99000–25160 (water resistance grease or equivalent) 3) install the spacers (1), dust seals (2) and washers (3). Rear stabilizer removal and installation b931h22306015 removal ...

  • Page 339

    Rear suspension: 2c-16 • install the washers (1) as shown. • tighten the stabilizer joint nuts (2) to the specified torque. Tightening torque rear stabilizer joint nut (a): 60 n·m (6.0 kgf-m, 43.5 lbf-ft) stabilizer parts inspection b931h22306016 refer to “rear stabilizer removal and installation (p...

  • Page 340

    2c-17 rear suspension: specifications service data b931h22307001 suspension tightening torque specifications b931h22307002 note the specified tightening torque is described in the following. “rear suspension components (page 2c-1)” “rear suspension assembly construction (page 2c-2)” reference: for t...

  • Page 341

    Rear suspension: 2c-18 special tool b931h22308002 09900–06108 09913–50121 snap ring remover (close type) oil seal remover )(page 2c-7) / )(page 2c- 8) )(page 2c-6) / )(page 2c- 7) 09913–70210 09913–75520 bearing installer set (10 – 75) bearing installing tool )(page 2c-7) )(page 2c-7) 09923–73210 09...

  • Page 342: Wheels and Tires

    2d-1 wheels and tires: suspension wheels and tires precautions precautions for wheel and tire b931h22400001 warning ! • proper tire pressure and proper tire loading are important factors. Over loading tire can lead to tire failure and loss of vehicle control. • using improper tires or tires with imp...

  • Page 343

    Wheels and tires: 2d-2 front / rear wheel removal and installation b931h22406002 note the front and rear wheels are installed symmetrically and therefore the removal procedure for one side is the same as that for the other side. Removal 1) place the vehicle on level ground. 2) support the vehicle wi...

  • Page 344

    2d-3 wheels and tires: 4) separate the tire from the rim using a set of tire levers and rim protectors. Caution ! When using the tire levers, do not scratch or hit the sealing portion (hump) of the wheel or it may cause air-leakage. 5) after removing the tire, inspect the wheel if necessary. Install...

  • Page 345

    Wheels and tires: 2d-4 note check the “rim line” “b” cast on the tire sidewalls. It must be equidistant from the wheel rim all the way around. If the distance between the rim line and the wheel rim varies, this indicates that the bead is not properly seated. If this is so, deflate the tire completel...

  • Page 346

    2d-5 wheels and tires:.

  • Page 347: Section 3

    Table of contents 3- i 3 section 3 contents driveline / axle precautions .................................................3-1 precautions............................................................. 3-1 precautions for driveline / axle ............................. 3-1 drive chain / drive train / dr...

  • Page 348

    3-ii table of contents special tool ......................................................3c-16 propeller shafts ....................................... 3d-1 repair instructions ..............................................3d-1 front output shaft components .........................3d-1 front outpu...

  • Page 349: Precautions

    Precautions: 3-1 driveline / axle precautions precautions precautions for driveline / axle b931h23000001 refer to “general precautions: in section 00”. Warning ! Support the vehicle with a jack or wooden block when servicing the drive shafts and drive train..

  • Page 350

    3a-1 drive chain / drive train / drive shaft: driveline / axle drive chain / drive train / drive shaft diagnostic information and procedures drive shaft symptom diagnosis b931h23104001 repair instructions front drive shaft components b931h23106001 condition possible cause correction / reference item...

  • Page 351

    Drive chain / drive train / drive shaft: 3a-2 front drive shaft assembly removal and installation b931h23106002 removal 1) drain the front differential gear oil. Refer to “front differential gear oil inspection: in section 0b”. 2) remove the front wheel. Refer to “front / rear wheel removal and inst...

  • Page 352

    3a-3 drive chain / drive train / drive shaft: 2) slide the boot toward the center of the front drive shaft and remove the stopper ring from the outer race. 3) remove the outer race from the front drive shaft. 4) wipe off any grease and remove the snap ring. Special tool (a): 09900–06107 (snap ring r...

  • Page 353

    Drive chain / drive train / drive shaft: 3a-4 2) install the cage (1) on the shaft. Caution ! Install the cage with the large diameter side “a” facing the shaft end. 3) install the new snap ring to the cage. Caution ! Replace the snap ring with a new one. Special tool (a): 09900–06107 (snap ring rem...

  • Page 354

    3a-5 drive chain / drive train / drive shaft: 8) install the circlip (2) into the groove of front drive shaft spline. Caution ! The removed circlip must be replaced with a new one. 9) inspect the axle play by using a push-and-pull motion given to the axle shaft and wheel spindle. Front drive shaft i...

  • Page 355

    Drive chain / drive train / drive shaft: 3a-6 rear drive shaft components b931h23106005 rear drive shaft assembly removal and installation b931h23106006 removal 1) drain the rear final gear oil. Refer to “final gear oil inspection: in section 0b”. 2) remove the rear wheel. Refer to “front / rear whe...

  • Page 356

    3a-7 drive chain / drive train / drive shaft: installation install the rear drive shaft in the reverse order of removal. Pay attention to the following points: • install a new circlip (1) into the groove of drive shaft spline. Caution ! The removed circlip must be replaced with a new one. • apply gr...

  • Page 357

    Drive chain / drive train / drive shaft: 3a-8 special tools and equipment recommended service material b931h23108001 note required service material is also described in the following. “front drive shaft components (page 3a-1)” “rear drive shaft components (page 3a-6)” special tool b931h23108002 mate...

  • Page 358: Differential

    3b-1 differential: driveline / axle differential diagnostic information and procedures drive train symptom diagnosis b931h23204001 dtc “c20” (p1752) diff-lock relay circuit malfunction b931h23204002 refer to “dtc “c20” (p1752): diff-lock relay circuit malfunction: in section 1a”. Condition possible ...

  • Page 359

    Differential: 3b-2 repair instructions front drive (differential) components b931h23206001 fwd fwd 1 2 3 4 5 6 7 8 9 10 11 12 13 15 17 16 14 18 19 20 21 25 26 28 22 23 24 27 29 (a) 30 31 (c) 32 29 (d) 33 (e) 34 (b) (a) 30 i931h1320095-04 1. Front drive (differential) gear case 16. Snap ring 31. Brea...

  • Page 360

    3b-3 differential: front drive (differential) construction b931h23206002 1 (b) 2 3 1 “a” (a) i931h1320001-03 1. Shim : 1.3 n ⋅m (0.13 kgf-m, 0.94 lbf-ft) : apply thread lock to the thread part. 2. Front drive (differential) case cover bolt : 22 n ⋅m (2.2 kgf-m, 16.0 lbf-ft) : apply bond to matching ...

  • Page 361

    Differential: 3b-4 front drive (differential) gear oil level inspection b931h23206003 refer to “front differential gear oil inspection: in section 0b”. Front drive (differential) gear oil replacement b931h23206004 refer to “front differential gear oil inspection: in section 0b”. Front drive (differe...

  • Page 362

    3b-5 differential: installation install the front drive (differential) assembly in the reverse order of removal. Pay attention to the following points: • apply grease to spline and inside of the front propeller shaft. : grease 99000–25160 (water resistance grease) • apply thread lock to the bolts an...

  • Page 363

    Differential: 3b-6 4) remove the front drive (differential) case housing (3) with the special tool. Special tool (a): 09912–34510 (cylinder disassembly ring tool) 5) remove the front drive (differential) gear assembly (4) and shims. 6) remove the diff-lock sleeve (5). 7) remove the diff-lock fork sh...

  • Page 364

    3b-7 differential: 11) remove the snap ring (11) and bearing (12). Note there is no abnormal noise, the bearing removal is not necessary. Special tool : 09900–06107 (snap ring remover (open type)) 12) remove the diff-lock cam (13). 13) remove the bearing (14) and oil seal (15) with the special tools...

  • Page 365

    Differential: 3b-8 17) remove the snap ring (21) and input shaft bearing (22) with the special tool. Note if there is no abnormal noise, the bearing removal is not necessary. Special tool : 09900–06107 (snap ring remover (open type)) (d): 09913–60910 (bearing and gear puller) 18) remove the snap rin...

  • Page 366

    3b-9 differential: assembly caution ! The removed oil seals, snap rings and bearings must be replaced with new ones. 1) install the bearings (1) with the special tool. Special tool (a): 09913–70210 (bearing installer set (10 – 75)) 2) install the pinion gear pilot bearing (2) with the special tool. ...

  • Page 367

    Differential: 3b-10 8) install the input shaft (9) and snap ring (10). Special tool : 09900–06107 (snap ring remover (open type)) 9) apply a small quantity of grease to the dust seal lip. : grease 99000–25010 (suzuki super grease a or equivalent) 10) install the dust seal with the special tool. Spec...

  • Page 368

    3b-11 differential: 14) install the differential fork (14) and screw shaft (15). Note when installing the screw shaft (15), align the convex part “a” of differential fork (14) and groove “b” of screw shaft (15). 15) install the convex part “c” of screw shaft (15) to the concave part “d” of diff-lock...

  • Page 369

    Differential: 3b-12 21) apply bond to the mating surface of the front drive (differential) case. : sealant 99000–31110 (suzuki bond no.1215 or equivalent) 22) align the differential fork (21) and groove “g” of the differential sleeve when reassembling. 23) apply a small quantity of thread lock to th...

  • Page 370

    3b-13 differential: front drive (differential) related parts inspection b931h23206007 refer to “front drive (differential) assembly disassembly and assembly (page 3b-5)”. Front drive gear oil seals inspect the lip of oil seal for wear or damage. If any defect is found, replace the oil seal with a ne...

  • Page 371

    Differential: 3b-14 diff-lock cam inspect the diff-lock cam for wear or damage. If any defects are found, replace the diff-lock cam with a new one. Differential sleeve inspect the differential sleeve for wear or damage. If any defects are found, replace the differential sleeve with a new one. Diff-l...

  • Page 372

    3b-15 differential: breather rubber case inspection b931h23206008 inspect the breather rubber case for wear or damage. If any defects are found, replace the breather rubber case with a new one. Front drive (differential) gear shim inspection and adjustment b931h23206009 refer to “front drive (differ...

  • Page 373

    Differential: 3b-16 • remove the dial gauge and turn the front drive (differential) gear 120 °, then measure the backlash. Repeat this procedure once more and compare the difference of the three measurements. If the backlash should be re-checked until the backlash is within specification. Check the ...

  • Page 374

    3b-17 differential: • remove the front drive (differential) case. • measure the thickness of compressed solder (2) with the micrometer. Special tool (a): 09900–20205 (micrometer (0 – 25 mm)) • select the proper size of shim(s) from the table, according the compressed solder thickness. List of shims ...

  • Page 375

    Differential: 3b-18 • rotate the final drive (differential) gear several turns in each direction. This will provide a contact pattern on the coated teeth of final drive (differential) gear. • remove the final drive (differential) gear and compare the coated teeth to the examples shown in [a], [b] an...

  • Page 376

    3b-19 differential: 2) inspect the diff-lock actuator diode (1) as shown in the neutral relay diode inspection. Refer to “neutral relay diode inspection: in section 1i”. 2wd/4wd/diff-lock switch continuity check 1) remove the left inner fender. Refer to “front side exterior parts removal and install...

  • Page 377

    Differential: 3b-20 3) click the “date monitor” button (3). 4) check that both “differential lock position switch signal” and “differential lock switch signal” are “open”. 5) turn the transfer selecting switch (diff-lock position switch and diff-lock switch) on position. 6) check that both “differen...

  • Page 378

    3b-21 differential: drive relay 1) remove the seat. Refer to “front side exterior parts removal and installation: in section 9d”. 2) remove the drive relay (1). 3) check the continuity between “a” and “d”, between “d” and “f” terminals with the multi-circuit tester. Check the insulation between “a” ...

  • Page 379

    Differential: 3b-22 rear drive breather hose routing diagram b931h23206011 1 2 2 3 1 5 6 “a” “b” “ a ” fwd 4 i831g1320145-02 1. Breather hose 6. V-belt cooling duct 2. Rear drive assembly “a”: press the breather hose between the fuel tank lower cover and belt cooling duct. 3. Clamp “b”: face the tip...

  • Page 380

    3b-23 differential: final gear components b931h23206012 1 2 3 4 5 6 7 8 9 10 11 12 13 (a) 14 (a) 15 (b) 16 (c) 17 (d) 17 (d) 18 (d) 19 fwd fwd 20 (e) i831g1320080-08 1. Final gear case 11. Shim : 100 n ⋅m (10.0 kgf-m, 72.0 lbf-ft) 2. Final gear case cover 12. Final drive gear : 26 n ⋅m (2.6 kgf-m, 1...

  • Page 381

    Differential: 3b-24 final gear construction b931h23206013 (c) (b) 6 (b) 5 (b) 4 3 “a” 1 (a) “a” 2 fwd (d) (a) i931h1320084-05 1. Shim (left side) 6. Lock-nut : 55 n ⋅m (5.5 kgf-m, 40.0 lbf-ft) 2. Shim (right side) “a”: matching surface : apply grease. 3. Final drive gear shim(s) : 26 n ⋅m (2.6 kgf-m...

  • Page 382

    3b-25 differential: final gear oil level inspection b931h23206014 refer to “final gear oil inspection: in section 0b”. Final gear oil replacement b931h23206015 refer to “final gear oil inspection: in section 0b”. Final gear assembly removal and installation b931h23206016 removal 1) remove the traile...

  • Page 383

    Differential: 3b-26 installation install the final gear assembly in the reverse order of removal. Pay attention to the following points: • apply 4.5 gram water resistance grease to the spline of the rear propeller shaft. : grease 99000–25160 (water resistance grease) • install the final gear case as...

  • Page 384

    3b-27 differential: 3) remove the final gear cover (2) from the final gear case, by using two 5 mm screws. 4) remove the o-ring (3) and final driven gear (4). 5) remove the shim(s) (5). 6) remove the oil seal (6) with the special tool. Special tool (a): 09913–50121 (oil seal remover) 7) remove the f...

  • Page 385

    Differential: 3b-28 10) remove the final driven gear bearing (9) with the suitable tool. Note if there is no abnormal condition, the bearing removal is not necessary. 11) unlock the final drive stopper (10) with a chisel. 12) remove the final drive stopper (11) with the special tool. Special tool (d...

  • Page 386

    3b-29 differential: 16) remove the washer (15). 17) remove the bearing (16) and the upper inner race from the pinion gear with the special tool and suitable tool. Note if there is no abnormal condition, the bearing removal is not necessary. Special tool (g): 09913–61510 (bearing puller) 18) remove t...

  • Page 387

    Differential: 3b-30 • install the final drive gear bearing (1) to the final gear case with the special tool. Special tool (a): 09913–70210 (bearing installer set (10 – 75)) • install the final drive bearing (2) with the special tool. Special tool (c): 09913–75520 (bearing installing tool) • install ...

  • Page 388

    3b-31 differential: • tighten the final drive gear bearing stopper (7) to the specified torque with the special tool. Caution ! The removed final drive gear bearing stopper must be replaced with a new one. Tightening torque final drive gear bearing stopper (b): 100 n·m ( 10.0 kgf-m, 72.5 lbf-ft) spe...

  • Page 389

    Differential: 3b-32 • install the oil seal with the special tool. Special tool (g): 09951–15810 (brake disk dust cover installer) • apply a small quantity of grease to the oil seal lip. : grease 99000–25160 (water resistance grease) • install the final driven gear (8) and shim(s) (9) into the final ...

  • Page 390

    3b-33 differential: final driven / drive gear bering inspect the bearings for abnormal noise and smooth rotation. Replace the bearings if there is anything unusual. Final drive gear inspect the final drive gear for wear or damage. Inspect the final drive gear bearing for abnormal noise and smooth ro...

  • Page 391

    Differential: 3b-34 • install the left side shim(s) and final driven gear. Special tool : 09900–20607 (dial gauge) : 09900–20701 (dial gauge chuck) final gear backlash standard: 0.02 – 0.06 mm (0.0008 – 0.0024 in) (without gear cover specification) standard: 0.08 – 0.15 mm (0.0031 – 0.0059 in) (gear...

  • Page 392

    3b-35 differential: • remove the final gear cover. • measure the thickness of compressed solder with the micrometer. Special tool : 09900–20205 (micrometer (0 – 25 mm)) shim thickness compressed solder thickness + 0.10 mm • select the proper size of shim(s) from the table, according as the compresse...

  • Page 393

    Differential: 3b-36 • install the final gear cover, and then tighten the bolts to the specified torque diagonally. Refer to “final gear assembly disassembly and assembly (page 3b-26)”. Note at this time, it is not necessary to install the gear case cover’s o-ring. • rotate the final driven gear seve...

  • Page 394

    3b-37 differential: specifications service data b931h23207001 drive train unit: mm (in) tightening torque specifications b931h23207002 note the specified tightening torque is described in the following. “front drive (differential) components (page 3b-2)” “front drive (differential) construction (pag...

  • Page 395

    Differential: 3b-38 special tools and equipment recommended service material b931h23208001 note required service material is also described in the following. “front drive (differential) components (page 3b-2)” “front drive (differential) construction (page 3b-3)” “final gear components (page 3b-23)”...

  • Page 396

    3b-39 differential: 09913–60910 09913–61510 bearing and gear puller bearing puller )(page 3b-8) / )(page 3b- 8) / )(page 3b-29) )(page 3b-29) 09913–70210 09913–75520 bearing installer set (10 – 75) bearing installing tool )(page 3b-7) / )(page 3b- 8) / )(page 3b-9) / )(page 3b-9) / )(page 3b- 9) / )...

  • Page 397: Transfer

    Transfer: 3c-1 driveline / axle transfer diagnostic information and procedures transfer symptom diagnosis b931h23304001 condition possible cause correction / reference item engine is noisy (noise seems to come from the transfer) worn or rubbing gear. Replace. Worn transfer driveshaft or countershaft...

  • Page 398

    3c-2 transfer: repair instructions transfer components b931h23306001 1 1 2 3 5 6 10 20 20 12 13 14 15 16 17 14 18 4 21 19 22 23 24 25 26 28 29 30 33 27 fwd fwd 8 7 11 35 32 31 34 9 i931h1330001-04 1. Washer 15. Select sliding dog 29. Drive gear no. 2 2. Reverse idle gear 16. Reverse select spacer 30...

  • Page 399

    Transfer: 3c-3 transfer removal and installation b931h23306002 removal 1) remove the engine assembly from the frame. Refer to “engine assembly removal: in section 1d”. 2) remove the engine top side. Refer to “engine top side disassembly: in section 1d”. 3) separate the crankcase with the special too...

  • Page 400

    3c-4 transfer: 9) remove the drive bevel gear (9). Refer to “rear output shaft / drive bevel gear removal and installation: in section 3d”. 10) remove the transfer output shaft assembly (10) with a plastic mallet. Caution ! The transfer output driven gear and transfer output shaft is available only ...

  • Page 401

    Transfer: 3c-5 note after the backlash and tooth contact have been checked or adjusted, lock the drive bevel gear nut with a center punch. Refer to “driven / drive bevel gear shim inspection and adjustment: in section 3d”. • install the rear output shaft. Refer to “rear output shaft / drive bevel ge...

  • Page 402

    3c-6 transfer: transfer construction b931h23306003 transfer disassembly and assembly b931h23306004 refer to “transfer removal and installation (page 3c- 3)”. Disassembly caution ! Identify the position of each removed part. Organize the parts in their respective groups so that they can be reinstalle...

  • Page 403

    Transfer: 3c-7 assembly note • when reassembling the driven gears, attention must be given to the locations and positions of washers. The cross sectional view shows the correct position of the snap ring. Refer to “transfer construction (page 3c-6)”. • before installing the gears, coat lightly engine...

  • Page 404

    3c-8 transfer: transfer related bearing removal and installation b931h23306005 refer to “oil seal / bearing (crankcase and generator cover) removal and installation: in section 1d” and “transfer disassembly and assembly (page 3c-6)”. Transfer related parts inspection b931h23306006 refer to “transfer...

  • Page 405

    Transfer: 3c-9 driveshaft bearing / countershaft bearing / gearshift bearing refer to “oil seal / bearing (crankcase and generator cover) removal and installation: in section 1d”. Oil seal refer to “oil seal / bearing (crankcase and generator cover) removal and installation: in section 1d”. Gearshif...

  • Page 406

    3c-10 transfer: gearshift system construction b931h23306008 gearshift cam disassembly and assembly b931h23306009 refer to “transfer removal and installation (page 3c- 3)”. Disassembly caution ! Identify the position of each removed part. Organize the parts in their respective groups so that they can...

  • Page 407

    Transfer: 3c-11 2) remove the spring (3) and washer (4). Assembly assemble the gearshift cam in the reverse order of disassembly. Pay attention to the following points: note when reassembling the gearshift cam, attention must be given to the location and position of washer and snap ring. The cross s...

  • Page 408

    3c-12 transfer: 5) disconnect the clamp and remove the gear position switch (3). Installation install the gear position switch in the reverse order of removal. Pay attention to the following points: • apply grease to the o-ring. Caution ! Replace the o-ring with a new one. : grease 99000–25010 (suzu...

  • Page 409

    Transfer: 3c-13 gearshift shaft no. 2 / gearshift cam plate removal and installation b931h23306013 removal refer to “shift lever assembly removal and installation: in section 5a”. 1) drain engine oil. Refer to “engine oil and filter replacement: in section 0b”. 2) remove the generator cover. Refer t...

  • Page 410

    3c-14 transfer: • check the gearshift cam stopper moves smoothly. • locate the gearshift cam in the neutral position. • install the gearshift cam stopper plate (5). Note • align the gearshift cam pin “b” with the gearshift cam stopper plate hole “c”. • tighten the gearshift cam stopper plate bolt se...

  • Page 411

    Transfer: 3c-15 gearshift shaft oil seal inspect the gearshift shaft oil seal lip for damage or wear. If any defect are found, replace the oil seal with a new one. Gearshift shaft oil seal removal and installation b931h23306015 removal • remove the generator cover. Refer to “generator removal and in...

  • Page 412

    3c-16 transfer: tightening torque specifications b931h23307002 reference: for the tightening torque of fastener not specified in this section, refer to “tightening torque list: in section 0c”. Special tools and equipment recommended service material b931h23308001 note required service material is al...

  • Page 413: Propeller Shafts

    Propeller shafts: 3d-1 driveline / axle propeller shafts repair instructions front output shaft components b931h23406001 front output shaft removal and installation b931h23406002 removal 1) remove the engine assembly from the frame. Refer to “engine assembly removal: in section 1d”. 2) remove the en...

  • Page 414

    3d-2 propeller shafts: 4) remove the front output shaft (1) from the right crankcase. Installation install the front output shaft in the reverse order of removal. Pay attention to the following points: note apply engine oil to each rotating part before reassembling. • apply a small quantity of greas...

  • Page 415

    Propeller shafts: 3d-3 5) remove the oil seal (9) with the special tool. Special tool (b): 09913–50121 (oil seal remover) 6) remove the snap ring (10) and washer (11). Special tool : 09900–06108 (snap ring remover (close type)) 7) remove the front output shaft bearing (front) with the special tool. ...

  • Page 416

    3d-4 propeller shafts: 2) install the front output shaft bearing (front) (2) to the front output shaft housing with the special tool. Special tool (a): 09913–70210 (bearing installer set (10 – 75)) 3) install the washer (3) and snap ring (4). Special tool : 09900–06108 (snap ring remover (close type...

  • Page 417

    Propeller shafts: 3d-5 front output shaft related parts inspection b931h23406004 refer to “front output shaft disassembly and assembly (page 3d-2)”. Front output shaft inspect the front output shaft for distortion. If distortion is found, replace the front output shaft with a new one. Inspect the ge...

  • Page 418

    3d-6 propeller shafts: rear output shaft components b931h23406005 rear output shaft / drive bevel gear removal and installation b931h23406006 removal rear output shaft 1) remove the engine assembly from the frame. Refer to “engine assembly removal: in section 1d”. 2) remove the engine top side. Refe...

  • Page 419

    Propeller shafts: 3d-7 4) remove the rear output shaft (1). 5) remove the c-ring (2). Drive bevel gear 1) remove the transfer component parts. Refer to “transfer removal and installation: in section 3c”. 2) unlock the drive bevel gear nut (1) with a chisel. 3) hold the transfer output driven gear wi...

  • Page 420

    3d-8 propeller shafts: • hold the transfer output driven gear with the special tools and tighten the drive bevel gear nut (2) to the specified torque. Caution ! The removed drive bevel gear nut must be replaced with a new one. Special tool (a): 09920–53740 (clutch sleeve hub holder) (b): 09920–31020...

  • Page 421

    Propeller shafts: 3d-9 6) remove the universal joint (3). 7) unlock the rear output shaft nut with a chisel. 8) with the rear output shaft held immovable with a vise, remove the rear output shaft nut. 9) remove the washer (7), yoke (8), oil seal (9), bearing (10) and shim (11). 10) unlock the rear o...

  • Page 422

    3d-10 propeller shafts: assembly assemble the rear output shaft in the reverse order of disassembly. Pay attention to the following points: note apply engine oil to each running part before reassembling. • install the rear output shaft driven bevel gear (1) and bearing (2). Note the wider side “a” o...

  • Page 423

    Propeller shafts: 3d-11 • with the rear output shaft held immovable with a vise, tighten the rear output shaft nut. Caution ! The removed rear output shaft nut must be replaced with a new one. Tightening torque rear output shaft nut (b): 100 n·m (10.0 kgf-m, 72.5 lbf-ft) • after the backlash and too...

  • Page 424

    3d-12 propeller shafts: rear output shaft related parts inspection b931h23406008 refer to “rear output shaft disassembly and assembly (page 3d-8)”. Rear output shaft inspect the rear output shaft for wear or damage. If any defects are found, replace the rear output shaft with a new one. Rear output ...

  • Page 425

    Propeller shafts: 3d-13 2) set the dial gauge on the drive bevel gear as shown. Special tool (b): 09900–20607 (dial gauge) (c): 09900–20701 (dial gauge chuck) 3) measure the backlash by turning the drive bevel gear shaft in each direction, reading the total backlash with the dial gauge. If the backl...

  • Page 426

    3d-14 propeller shafts: tooth contact caution ! Make sure to check the backlash after the tooth contact has been adjusted, since it may have changed. Adjust the tooth contact and backlash until they are both within specification. If the correct tooth contact cannot be maintained when adjusting the b...

  • Page 427

    Propeller shafts: 3d-15 final assembly 1) after adjusting the gear backlash and tooth contact correctly, remove the rear output shaft and drive bevel gear. 2) clean off any machinist’s dye or paste from the gear teeth, and lubricate the teeth with engine oil. 3) install the drive bevel gear and rear...

  • Page 428

    3d-16 propeller shafts: front propeller shaft removal and installation b931h23406011 removal 1) remove the front drive (differential) assembly. Refer to “front drive (differential) assembly removal and installation: in section 3b”. 2) remove the front propeller shaft spring (1) and front propeller s...

  • Page 429

    Propeller shafts: 3d-17 4) apply grease (approx. 4 grams) to the spline. : grease 99000–25160 (water resistance grease or equivalent) 5) connect the universal joint to the joint portion (at the engine side). 6) attach the boot to the front drive collar and tighten the boot clamp screw (3) to the spe...

  • Page 430

    3d-18 propeller shafts: universal joint inspect the play by turning the universal joint. If excessive play is noted, replace it with a new one. Caution ! Do not attempt to disassemble the universal joint. Boots inspect the front propeller shaft boot and universal joint boot for crack or damage. If a...

  • Page 431

    Propeller shafts: 3d-19 rear propeller shaft removal and installation b931h23406014 removal 1) remove the final gear assembly. Refer to “final gear assembly removal and installation: in section 3b”. 2) remove the rear propeller shaft joint (1). 3) remove the o-ring (2). 4) remove the rear propeller ...

  • Page 432

    3d-20 propeller shafts: 9) remove the circlips (8) from the universal joint. 10) remove the bearings (9) by tapping with the special tool and remove the universal joint and propeller shaft yoke. Special tool (a): 09913–70210 (bearing installer set (10 – 75)) 11) shift into the reverse gear. 12) unlo...

  • Page 433

    Propeller shafts: 3d-21 6) install the yoke (4). 7) install the bearings (5) by tapping with the special tool. Special tool (a): 09913–70210 (bearing installer set (10 – 75)) 8) install the circlips (6) to the universal joint. 9) install the rear propeller shaft boot (7) and tighten the clamp screw ...

  • Page 434

    3d-22 propeller shafts: 16) install the o-ring (13) to the rear propeller shaft joint (14). 17) apply grease (approx. 4 grams) to the spline of rear propeller shaft joint. : grease 99000–25160 (water resistance grease or equivalent) 18) install the rear propeller shaft joint (15). 19) install the fi...

  • Page 435

    Propeller shafts: 3d-23 2) insert the universal joint to the bearing and check the play by turning the universal joint, as shown in the figure. If excessive play is found, replace the bearings and universal joint as a set. Rear propeller shaft spring inspect the rear propeller shaft spring for wear ...

  • Page 436

    3d-24 propeller shafts: special tools and equipment recommended service material b931h23408001 note required service material is also described in the following. “front output shaft components (page 3d-1)” “rear output shaft components (page 3d-6)” “front propeller shaft components (page 3d-15)” “re...

  • Page 437

    Propeller shafts: 3d-25 special tool b931h23408002 09900–06107 09900–06108 snap ring remover (open type) snap ring remover (close type) )(page 3d-2) )(page 3d-3) / )(page 3d- 4) 09900–20607 09900–20701 dial gauge dial gauge chuck )(page 3d-13) )(page 3d-13) 09913–50121 09913–70210 oil seal remover b...

  • Page 438

    3d-26 propeller shafts:.

  • Page 439: Section 4

    Table of contents 4- i 4 section 4 contents brake precautions .................................................4-1 precautions............................................................. 4-1 precautions for brake system .............................. 4-1 brake fluid information .......................

  • Page 440

    4-ii table of contents parking / rear brake lever removal and installation .........................................................4d-4 parking / rear brake light switch inspection .....4d-4 parking / rear brake relay inspection ...............4d-4 specifications ......................................

  • Page 441: Precautions

    Precautions: 4-1 brake precautions precautions precautions for brake system b931h24000001 refer to “general precautions: in section 00”. Brake fluid information b931h24000002 warning ! • this brake system is filled with an ethylene glycol-based dot 4 brake fluid. Do not use or mix different types of...

  • Page 442

    4a-1 brake control system and diagnosis: brake brake control system and diagnosis schematic and routing diagram front brake hose routing diagram b931h24102001 1 “b” 2 “c” 3 4 5 5 7 4 (a) 8 9 4 (a) 8 9 10 11 11 12 (a) 8 11 “e” 6 “f” (b) “d” (b) “a” “d” “d” i931h1410043-05 1. Master cylinder 11. Suspe...

  • Page 443

    Brake control system and diagnosis: 4a-2 rear brake cable routing diagram b931h24102002 1 3 2 1 “a” 1 3 5 6 4 1 fwd fwd i931h1410044-02 1. Rear brake cable 3. Rear brake pedal 5. Washer “a”: fix the rear brake cable to the footrest bar with clamp. 2. Adjust nut 4. Pin 6. Cotter pin.

  • Page 444

    4a-3 brake control system and diagnosis: diagnostic information and procedures brake symptom diagnosis b931h24104001 repair instructions brake pedal height inspection and adjustment b931h24106001 refer to “rear brake pedal / rear brake (parking brake) lever inspection and adjustment: in section 0b”....

  • Page 445

    Brake control system and diagnosis: 4a-4 rear brake light switch inspection b931h24106003 inspect the rear brake light switch in the following procedures: 1) remove the left front inner fender. Refer to “front side exterior parts removal and installation: in section 9d”. 2) disconnect the rear brake...

  • Page 446

    4a-5 brake control system and diagnosis: air bleeding from front brake fluid circuit b931h24106009 air trapped in the brake fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cylinder and thus interferes with the full braking performance of the bra...

  • Page 447

    Brake control system and diagnosis: 4a-6 brake fluid replacement b931h24106010 caution ! • make sure that the vehicle is supported securely. • handle brake fluid with care: the fluid reacts chemically with paint, plastic, rubber materials, etc. 1) support the vehicle on a level surface with a jack a...

  • Page 448

    4a-7 brake control system and diagnosis: front brake hose removal and installation b931h24106011 removal caution ! Make sure that the vehicle is supported securely. 1) remove the front fender. Refer to “front side exterior parts removal and installation: in section 9d”. 2) drain brake fluid. Refer t...

  • Page 449

    Brake control system and diagnosis: 4a-8 6) remove the rear brake cable (6). 7) remove the rear brake cable adjuster nut (7) and cable (8). Installation 1) install the rear brake cable as shown in the rear brake cable routing diagram. Refer to “rear brake cable routing diagram (page 4a-2)”. 2) insta...

  • Page 450

    4a-9 brake control system and diagnosis: front brake master cylinder components b931h24106013 front brake master cylinder assembly removal and installation b931h24106014 removal 1) drain brake fluid. Refer to “brake fluid replacement (page 4a-6)”. 2) remove the throttle case assembly. Refer to “hand...

  • Page 451

    Brake control system and diagnosis: 4a-10 4) place a rag underneath the brake hose union bolt (2) on the master cylinder to catch any spilt brake fluid. 5) remove the brake hose union bolt (2) and disconnect the brake hose. 6) remove the master cylinder assembly (3). Installation install the front b...

  • Page 452

    4a-11 brake control system and diagnosis: front brake master cylinder / brake lever disassembly and assembly b931h24106015 refer to “front brake master cylinder assembly removal and installation (page 4a-9)”. Disassembly 1) remove the reservoir cap (1) and diaphragm (2). 2) remove the brake lever (3...

  • Page 453

    Brake control system and diagnosis: 4a-12 • when installing the brake light switch, align the projection on the switch with the hole in the master cylinder. • apply grease to the brake lever pivot bolt. • apply grease to the contact point between piston and brake lever. : grease 99000–25100 (suzuki ...

  • Page 454

    4a-13 brake control system and diagnosis: rear brake pedal construction b931h24106017 rear brake pedal removal and installation b931h24106018 removal 1) remove the right inner fender. Refer to “front side exterior parts removal and installation: in section 9d”. 2) remove the right mud guard. Refer t...

  • Page 455

    Brake control system and diagnosis: 4a-14 5) remove the rear brake pedal shaft (3). 6) remove the rear brake pedal (4) and rear brake pedal spring (5). 7) remove the dust seals (6) if necessary. Caution ! If there are wear or damage, replace the dust seals (6) with new ones. 8) remove the washers (7...

  • Page 456

    4a-15 brake control system and diagnosis: specifications service data b931h24107001 brake unit: mm (in) oil tightening torque specifications b931h24107002 note the specified tightening torque is described in the following. “front brake hose routing diagram (page 4a-1)” “front brake master cylinder c...

  • Page 457

    Brake control system and diagnosis: 4a-16 special tools and equipment recommended service material b931h24108001 note required service material is also described in the following. “front brake master cylinder components (page 4a-9)” “rear brake pedal construction (page 4a-13)” special tool b931h2410...

  • Page 458: Front Brakes

    4b-1 front brakes: brake front brakes precautions precautions for front brakes b931h24200001 warning ! When servicing the front brake system, place the vehicle on a level ground and support the vehicle with a jack. Note the right and left calipers, brake pads and discs are installed symmetrically an...

  • Page 459

    Front brakes: 4b-2 front brake pad inspection b931h24206002 the extent of brake pads wear can be checked by observing the grooved limit line “a” on the pads. When the wear exceeds the grooved limit line, replace the pads with new ones. Refer to “front brake pad replacement (page 4b-2)”. Caution ! Re...

  • Page 460

    4b-3 front brakes: 7) apply a small quantity of thread lock to the brake pad mounting pins (1). : thread lock cement 99000–32050 (thread lock cement 1342 or equivalent) 8) tighten the front brake pad mounting pins (1) to the specified torque. Tightening torque front brake pad mounting pin (a): 18 n·...

  • Page 461

    Front brakes: 4b-4 • after setting the brake hose union to the stopper, tighten the union bolt (3) to the specified torque. Caution ! The seal washers (4) should be replaced with the new ones to prevent fluid leakage. Tightening torque front brake hose union bolt (b): 23 n·m (2.3 kgf- m, 16.5 lbf-ft...

  • Page 462

    4b-5 front brakes: 6) remove the piston seal (6) and dust seal (7). Assembly assemble the caliper in the reverse order of disassembly. Pay attention to the following points: • wash the caliper bores and pistons with specified brake fluid. Particularly wash the dust seal groove and piston seal groove...

  • Page 463

    Front brakes: 4b-6 front brake caliper parts inspection b931h24206006 refer to “front brake caliper disassembly and assembly (page 4b-4)”. Brake caliper cylinder inspect the brake caliper cylinder wall for nicks, scratches or other damage. If any damage is found, replace the caliper with a new one. ...

  • Page 464

    4b-7 front brakes: front brake disc removal and installation b931h24206007 removal 1) remove the front wheel assembly. Refer to “front / rear wheel removal and installation: in section 2d”. 2) remove the front wheel hub. Refer to “front wheel hub / steering knuckle removal and installation: in secti...

  • Page 465

    Front brakes: 4b-8 specifications service data b931h24207001 brake unit: mm (in) oil tightening torque specifications b931h24207002 note the specified tightening torque is described in the following. “front brake components (page 4b-1)” reference: for the tightening torque of fastener not specified ...

  • Page 466

    4b-9 front brakes: special tool b931h24208002 09900–20205 09900–20607 micrometer (0 – 25 mm) dial gauge )(page 4b-7) )(page 4b-7) 09900–20701 dial gauge chuck )(page 4b-7).

  • Page 467: Rear Brakes

    Rear brakes: 4c-1 brake rear brakes precautions precautions for rear brake b931h24300001 warning ! When servicing the rear brake system, place the vehicle on a level ground and support the vehicle with a jack. Repair instructions rear brake components b931h24306001 1 2 3 5 4 7 8 9 10 11 12 13 (a) 17...

  • Page 468

    4c-2 rear brakes: rear brake friction plate inspection b931h24306002 refer to “rear brake friction plate wear limit inspection: in section 0b”. Rear brake friction plate replacement b931h24306003 refer to “rear brake disassembly and assembly (page 4c-3)”. Rear brake assembly removal and installation...

  • Page 469

    Rear brakes: 4c-3 • install the return spring (3) and lining indicator (4). Note align the boss of lining indicator (4) with wide spline on the brake cam shaft. • install the rear brake cam lever (5) to the rear brake cam shaft. Note when installing the brake cam lever, align the punched mark “d” wi...

  • Page 470

    4c-4 rear brakes: 5) unlock the nut with a chisel. 6) remove the rear drive gear shaft nut (6) with the special tool and remove the washer (7). Special tool (a): 09924–52420 (secondary bevel gear holder) 7) remove the rear drive gear shaft (8), with plastic mallet. 8) remove the oil seal (9) with th...

  • Page 471

    Rear brakes: 4c-5 12) remove the side plate stopper (13). 13) remove the side plate (14), pins (15) and springs (16). 14) separate the friction plates (17) and separator plates (18). Assembly caution ! The removed oil seal, bearing and snap ring must be replaced with new ones. • install the rear bra...

  • Page 472

    4c-6 rear brakes: • apply grease to the lip of oil seals. : grease 99000–25160 (water resistance grease) • install the rear final drive gear shaft (9). Note if the rear final drive gear shaft not install easily, lightly tap it using a plastic mallet. • install the rear brake cam shaft (10). • apply ...

  • Page 473

    Rear brakes: 4c-7 • install the balls and rear brake pressure plate (14). Note when installing the rear brake pressure plate (14), align its groove “a” with the cam “b” of rear brake cam shaft (10). • install the rear brake plates (15), aligning the grooves “c” of the case. Note align the side plate...

  • Page 474

    4c-8 rear brakes: rear brake cam shaft inspect the rear brake cam shaft for wear or damage. If any wear or damage is found, replace it with a new one. Rear drive gear shaft inspect the rear drive gear shaft for wear or damage. If any defects are found, replace rear drive gear shaft with a new one. R...

  • Page 475

    Rear brakes: 4c-9 rear brake pressure plate inspect the rear brake pressure plate for wear or damage. If any wear or damage is found, replace it with a new one. Inspect the balls for wear or damage. If any wear or damage is found, replace them with new ones. Specifications service data b931h24307001...

  • Page 476

    4c-10 rear brakes: special tools and equipment recommended service material b931h24308001 note required service material is also described in the following. “rear brake components (page 4c-1)” special tool b931h24308002 material suzuki recommended product or specification note grease water resistanc...

  • Page 477: Parking Brake

    Parking brake: 4d-1 brake parking brake schematic and routing diagram parking / rear brake cable routing diagram b931h24402001 1 “a” 1 3 3 4 1 “b” 4 2 1 i931h1440001-03 1. Parking brake cable 4. Wiring harness 2. Parking brake cable guide “a”: pass the parking brake cable under the wiring harness. 3...

  • Page 478

    4d-2 parking brake: 1 1 6 4 3 2 5 1 6 “c” 3 1 8 7 i931h1440002-02 1. Parking brake cable 6. Clamp 2. Parking brake cable guide 7. Parking brake cable adjust nut 3. Frame 8. Rear brake assembly 4. Wiring harness “c”: fix the rubber of parking brake cable with clamp. 5. Rear fender.

  • Page 479

    Parking brake: 4d-3 repair instructions parking / rear brake inspection and adjustment b931h24406001 refer to “rear brake pedal / rear brake (parking brake) lever inspection and adjustment: in section 0b”. Parking / rear brake cable removal and installation b931h24406002 removal 1) remove the seat. ...

  • Page 480

    4d-4 parking brake: parking / rear brake lever components b931h24406003 parking / rear brake lever removal and installation b931h24406004 removal refer to “handlebars removal and installation: in section 6b”. Installation refer to “handlebars removal and installation: in section 6b”. Parking / rear ...

  • Page 481

    Parking brake: 4d-5 specifications tightening torque specifications b931h24407001 note the specified tightening torque is described in the following. “parking / rear brake lever components (page 4d-4)” reference: for the tightening torque of fastener not specified in this section, refer to “tighteni...

  • Page 482

    4d-6 parking brake:.

  • Page 483: Section 5

    Table of contents 5- i 5 section 5 contents transmission / transaxle precautions .................................................5-1 precautions............................................................. 5-1 precautions for transmission / transaxle............. 5-1 automatic transmission............

  • Page 484: Precautions

    5-1 precautions: transmission / transaxle precautions precautions precautions for transmission / transaxle b931h25000001 refer to “general precautions: in section 00”..

  • Page 485: Automatic Transmission

    Automatic transmission: 5a-1 transmission / transaxle automatic transmission schematic and routing diagram drive train system b931h25102001 “a” 5 4 6 7 9 3 2 10 1 8 13 12 14 8 11 i931h1510001-03 1. Crankshaft 6. Fixed driven face 11. Low driven gear 2. Movable drive face 7. Transfer input shaft 12. ...

  • Page 486

    5a-2 automatic transmission: diagnostic information and procedures automatic transmission symptom diagnosis b931h25104001 condition possible cause correction / reference item excessive engine noise gear worn or abnormal contact. Replace. Spline worn. Replace. Bearing worn or burned. Replace. V-belt ...

  • Page 487

    Automatic transmission: 5a-3 repair instructions automatic transmission components b931h25106001 16 17 15 18 19 15 20 22 21 (a) 23 (b) 24 (a) 11 10 (a) 1 2 3 5 8 4 9 6 7 fwd fwd 12 14 13 19 25 i931h1510106-03 1. Drive face bolt 11. Driven face bolt 21. Spring 2. Movable drive plate 12. Clutch housin...

  • Page 488

    5a-4 automatic transmission: v-belt cooling duct construction b931h25106002 v-belt cooling duct removal and installation b931h25106003 removal 1) remove the right inner fender. Refer to “front side exterior parts removal and installation: in section 9d”. 2) loosen the clamp screw and remove the inle...

  • Page 489

    Automatic transmission: 5a-5 5) remove the outlet belt cooling duct no. 1 (4) along with outlet belt cooling duct connector (5). Installation 1) install the v-belt cooling duct as shown in the v-belt cooling duct construction. Refer to “v-belt cooling duct construction (page 5a-4)”. 2) install the r...

  • Page 490

    5a-6 automatic transmission: movable driven face 1) hold the movable driven face with the special tool and its remove the driven face bolt (1). 2) remove the driven face assembly (2) and drive belt (3). Special tool (a): 09930–40113 (flywheel rotor holder) fixed drive face remove the fixed drive fac...

  • Page 491

    Automatic transmission: 5a-7 movable driven face / drive v-belt • install the drive belt (1), as low as possible, between the movable driven face and fixed driven face by tapping with a plastic mallet. Caution ! • the drive belt should be installed so that the arrows on the drive belt periphery poin...

  • Page 492

    5a-8 automatic transmission: • install the collar (2) and drive face bolt (3). Note the deep concave of the collar (2) faces outside. • install the dowel pins (4). • tighten the movable drive face bolt (3) to the specified torque with the special tool. Tightening torque movable drive face bolt (a): ...

  • Page 493

    Automatic transmission: 5a-9 2) remove the movable drive plate (2) and rollers (3). 3) remove the dampers (4). 4) remove the oil seals (5) and (6). Note if there are no abnormal conditions, the oil seals removal are not necessary. Assembly 1) install the oil seals with the special tool. Special tool...

  • Page 494

    5a-10 automatic transmission: 5) assemble the movable plate (4) to the movable drive face (2). 6) apply grease to the inside groove of the spacer (5). : grease 99000–25010 (suzuki super grease a or equivalent) 7) install the spacer (6). Note when installing the spacer, press down the movable drive f...

  • Page 495

    Automatic transmission: 5a-11 3) remove the movable driven face ring nut (2). Warning ! Since a high spring force applies to the movable driven face, care must be used so as not to cause the movable driven face to come off abruptly. 1) loosen the special tool handle slowly and remove the special too...

  • Page 496

    5a-12 automatic transmission: assembly assemble the movable driven face in the reverse order of disassembly. Pay attention to the following points: • install the oil seals (1) with the special tool. Special tool (a): 09913–70210 (bearing installer set (10 – 75)) caution ! The removed oil seals must ...

  • Page 497

    Automatic transmission: 5a-13 • install the spring (8) and spring plate (9) by aligning the spring ends with the holes. Note when installing the spring (8), set the paint mark side of the spring (8) to the movable driven face side. • compress the spring (8) with the special tool. Special tool (b): 0...

  • Page 498

    5a-14 automatic transmission: drive v-belt inspection b931h25106008 inspect that the drive belt is free from any greasy substance. Inspect the contact surface of the drive belt for cracks or damage and measure the width of the drive belt with the vernier calipers. If any defects are found or measure...

  • Page 499

    Automatic transmission: 5a-15 movable / fixed driven face parts inspection b931h25106010 movable / fixed driven face inspect the driven face for any abnormal conditions, such as stepped wear or discoloration caused by burning. If any defects are found, replace them with new ones. Movable driven pin ...

  • Page 500

    5a-16 automatic transmission: 6) remove the dowel pins (6) and gasket (7). 7) remove the one way clutch (8). 8) hold the clutch shoe with the special tools and remove the clutch shoe nut (9). Caution ! The clutch shoe nut (9) has left-hand threads. Special tool (a): 09930–40113 (flywheel rotor holde...

  • Page 501

    Automatic transmission: 5a-17 • apply a small quantity of thread lock to the clutch shoe nut (3). : thread lock cement 99000–32030 (thread lock cement super 1303 or equivalent) • install the clutch shoe nut (3). Note the clutch shoe nut (3) has left-hand threads. • tighten the clutch shoe nut (3) to...

  • Page 502

    5a-18 automatic transmission: • install the outlet belt cooling duct connector (9). Clutch cover disassembly and assembly b931h25106012 refer to “clutch shoe removal and installation (page 5a-15)”. Disassembly • remove the clutch housing (1) from clutch cover. • remove the spacer (2). • remove the o...

  • Page 503

    Automatic transmission: 5a-19 assembly • install the bearing (1) with the special tool. Special tool (a): 09913–70210 (bearing installer set (10 – 75)) caution ! The removed bearing must be replaced with a new one. • fit the bearing retainers (2). • apply a small quantity of thread lock to the beari...

  • Page 504

    5a-20 automatic transmission: • after installed the clutch housing, check if the clutch housing rotates smoothly. Clutch related parts inspection b931h25106013 refer to “clutch cover disassembly and assembly (page 5a-18)”. Clutch shoe inspect the boss and centrifugal weight fulcrum sections for loos...

  • Page 505

    Automatic transmission: 5a-21 • install the clutch shoe (3) onto the clutch housing and turn the clutch shoe by hand to inspect the one way clutch for a smooth movement. The clutch shoe turns one direction only. If a large resistance is felt to rotation, inspect the one way clutch for damage or one ...

  • Page 506

    5a-22 automatic transmission: • apply grease to the bearing. : grease 99000–25010 (suzuki super grease a or equivalent) • install the snap ring (2). Caution ! The removed snap ring must be replaced with a new one. • install the oil seal (3) with the special tool. Special tool (a): 09913–70210 (beari...

  • Page 507

    Automatic transmission: 5a-23 shift lever assembly components b931h25106016 gearshift knob removal and installation b931h25106017 removal 1) loosen the lock-nut (1). 2) remove the gearshift knob (2). Installation install the gearshift knob in the reverse order of removal. Note tighten the lock-nut s...

  • Page 508

    5a-24 automatic transmission: 6) remove the shift lever assembly (4). Installation install the gearshift lever in the reverse order of removal. Pay attention to the following points: • apply grease to pivot. : grease 99000–25010 (suzuki super grease a or equivalent) • tighten shift lever assembly mo...

  • Page 509

    Automatic transmission: 5a-25 shift rod adjustment b931h25106020 adjust the shift rod length along each angle of the gearshift link arm. 1) loosen the lock-nuts (1). 2) turn shift rod in or out and set the gearshift link arm angle as shown in the figure. Specifications service data b931h25107001 clu...

  • Page 510

    5a-26 automatic transmission: tightening torque specifications b931h25107002 note the specified tightening torque is described in the following. “automatic transmission components (page 5a-3)” “shift lever assembly components (page 5a-23)” reference: for the tightening torque of fastener not specifi...

  • Page 511

    Automatic transmission: 5a-27 special tool b931h25108002 09900–20101 09913–50121 vernier calipers (150 mm) oil seal remover )(page 5a-14) )(page 5a-18) / )(page 5a-21) 09913–70210 09917–23711 bearing installer set (10 – 75) ring nut socket wrench )(page 5a-9) / )(page 5a- 12) / )(page 5a-19) / )(pag...

  • Page 512

    5a-28 automatic transmission:.

  • Page 513: Section 6

    Table of contents 6- i 6 section 6 contents steering precautions .................................................6-1 precautions............................................................. 6-1 precautions for steering ....................................... 6-1 steering general diagnosis.............

  • Page 514: Precautions

    6-1 precautions: steering precautions precautions precautions for steering b931h26000001 refer to “general precautions: in section 00”..

  • Page 515: Steering General Diagnosis

    Steering general diagnosis: 6a-1 steering steering general diagnosis diagnostic information and procedures steering symptom diagnosis b931h26104001 condition possible cause correction / reference item heavy steering distorted steering shaft. Replace. Improper front wheel alignment. Adjust. Insuffici...

  • Page 516: Steering / Handlebar

    6b-1 steering / handlebar: steering steering / handlebar repair instructions steering / handlebars components b931h26206001 1 2 3 4 5 6 7 8 12 13 14 15 16 17 18 12 “a” “a” “a” 12 20 20 19 “a” (a) 10 11 9 i931h1620036-08 1. Handlebars 10. Lower dust seal 19. Handlebar left switch assembly 2. Handleba...

  • Page 517

    Steering / handlebar: 6b-2 steering / handlebars assembly construction b931h26206002 (a) (a) (f) (e) 6 (d) 3 (c) 4 (c) 2 (d) 3 (c) 2 (a) “b” view a a 5 (a) (b) 1 i931h1620037-06 1. Handlebar holder nut : 60 n ⋅m (6.0 kgf-m, 43.5 lbf-ft) 2. Tie-rod end nut : 29 n ⋅m (2.9 kgf-m, 21.0 lbf-ft) 3. Steeri...

  • Page 518

    6b-3 steering / handlebar: handlebars removal and installation b931h26206003 removal 1) remove the combination meter. Refer to “combination meter removal and installation: in section 9c”. 2) remove the clamp. 3) disconnect the brake hose from the hose guide. 4) remove the following parts from the ha...

  • Page 519

    Steering / handlebar: 6b-4 9) remove the left brake lever (9) from the handlebars (left side). Installation install the handlebars in the reverse order of removal. Pay attention to the following points: • install the left brake lever (1) to the handlebars. • align the punch mark “a” on the handlebar...

  • Page 520

    6b-5 steering / handlebar: • tighten the left handlebar switch screws (6). • install the master cylinder. Refer to “front brake master cylinder assembly removal and installation: in section 4a”. • align the punch mark “e” on the handlebars with the mating surface “f” of the throttle lever case. • ti...

  • Page 521

    Steering / handlebar: 6b-6 4) remove the cotter pin (1), nut (2) and washer (3). 5) remove the steering arm plate (4) and steering shaft (5). 6) remove the lower dust seal (6) and o-ring (7). 7) remove the steering shaft bushing (8) and dust seal (9) with the special tools and suitable socket wrench...

  • Page 522

    6b-7 steering / handlebar: • apply grease to the lower dust seal (3) and o-ring (4). Caution ! The removed o-ring must be replaced with a new one. : grease 99000–25160 (water resistance grease) • apply grease to the steering shaft. : grease 99000–25160 (water resistance grease) • install the steerin...

  • Page 523

    Steering / handlebar: 6b-8 tie-rod / tie-rod end removal and installation b931h26206006 warning ! When using the tie-rod end remover, keep clear of the tie-rod end because it may come loose with some force and could strike you. Removal 1) remove the tie-rod end with the special tool. Refer to “front...

  • Page 524

    6b-9 steering / handlebar: • install the washers (2) and tighten the rod end nuts (3) (steering arm plate side) to the specified torque. Tightening torque tie-rod end nut (b): 29 n·m (2.9 kgf-m, 21.0 lbf-ft) • install the cotter pins (4). Caution ! The removed cotter pins (4) must be replaced with n...

  • Page 525

    Steering / handlebar: 6b-10 wheel unit: mm tightening torque specifications b931h26207002 note the specified tightening torque is described in the following. “steering / handlebars components (page 6b-1)” “steering / handlebars assembly construction (page 6b-2)” reference: for the tightening torque ...

  • Page 526

    6b-11 steering / handlebar: special tool b931h26208002 09924–84521 09930–30721 bearing installer set rotor remover )(page 6b-6) / )(page 6b- 6) )(page 6b-6) 09942–72410 tie-rod end remover )(page 6b-5) / )(page 6b- 8) / )(page 6b-8).

  • Page 527

    Power assisted steering system: 6c-1 steering power assisted steering system precautions precautions for eps b931h26300001 refer to “precautions for electrical circuit service: in section 00”. Note when repairing eps system, remove the front fender. Refer to “front side exterior parts removal and in...

  • Page 528

    6c-2 power assisted steering system: general description p/s system description b931h26301001 this electronic power steering (eps) system consists of a eps control unit (2), a torque sensor (3), a eps motor (4). In this system, the eps control unit determines the level and direction of the assist fo...

  • Page 529

    Power assisted steering system: 6c-3 detecting principle the column shaft is connected to the input shaft by means of serration. The output shaft and input shaft are connected via torsion bar. When torque is inputted from the column shaft, a relative angular displacement occurs between the input sha...

  • Page 530

    6c-4 power assisted steering system: control system in the eps control unit, the steering assist control determines the basic power assist force and the convergence control improves the steering operation feeling. The controller determines the target motor current by the calculation of these control...

  • Page 531

    Power assisted steering system: 6c-5 eps diagnosis general description b931h26301002 the p/s system in this vehicle is controlled by the eps control unit. The eps control unit has an self diagnostic system which detects a malfunction in this system. When diagnosing troubles, be sure to have full und...

  • Page 532

    6c-6 power assisted steering system: schematic and routing diagram eps wiring diagram b931h26302001 refer to “wire color symbols: in section 0a”. On2 on1 off 12 3 45 6 1 ignition switch fuse box 1. Head hi 2. Head lo 3. Fuel 4. Ignition 5. F an 6. Power source 10 a 10 a 10 a 15 a 15 a 10 a st arter ...

  • Page 533

    Power assisted steering system: 6c-7 eps control unit diagram b931h26302002 refer to “wire color symbols: in section 0a”. Eps control unit coupler (eps control unit harness end) 30 a 40 a ignition switch eps main fail-safe relay eps motor speed sensor (vehicle speed) speedometer ecm motor drive circ...

  • Page 534

    6c-8 power assisted steering system: eps system wiring harness routing diagram b931h26302003 refer to “wiring harness routing diagram: in section 9a”. Component location eps components location b931h26303001 refer to “electrical components location: in section 0a”. Diagnostic information and procedu...

  • Page 535

    Power assisted steering system: 6c-9 information gathering to properly diagnose a malfunction, one must not make guesses or assumptions about the circumstances that caused it. Proper diagnosis and repair require duplicating the situation in which the malfunction occurred. If a diagnosis is made with...

  • Page 536

    6c-10 power assisted steering system: steering related parts refer to “steering related parts inspection: in section 6b”. Battery battery voltage inspection 1) turn the ignition switch off. 2) remove the seat. Refer to “seat removal and installation: in section 9d”. 3) measure the voltage between th...

  • Page 537

    Power assisted steering system: 6c-11 eps system check b931h26304003 warning ! Carry out test drive in light traffic area to prevent an accident. Step action yes no 1 1) perform “customer complaint analysis”. Was customer complaint analysis performed according to instruction? Go to step 2. Perform c...

  • Page 538

    6c-12 power assisted steering system: 4 (the eps indicator light does not light up) 1) turn the ignition switch off. 2) disconnect the eps control unit coupler (1) and (2). 3) turn the ignition switch on with the eps control unit coupler disconnected, measure the voltage between terminal “a” and ter...

  • Page 539

    Power assisted steering system: 6c-13 5 1) turn the ignition switch on with the eps control unit coupler disconnected, measure the voltage between terminal “a” and terminal “b” at the coupler. Special tool (a): 09900–25008 (multi-circuit tester set) tester knob indication voltage ( ) normal value (“...

  • Page 540

    6c-14 power assisted steering system: 7 (the eps indicator light does not go off) 1) remove the seat. Refer to “seat removal and installation: in section 9d”. 2) open the fuse box and inspect the ignition fuse (1). Caution ! If a fuse is blown, find the cause of the problem and correct it before rep...

  • Page 541

    Power assisted steering system: 6c-15 8 1) turn the ignition switch off. 2) disconnect the eps control unit coupler (1) and (2). 3) turn the ignition switch on with the eps control unit coupler disconnected, measure the voltage between terminal “a” and terminal “b” at the coupler. Special tool (a): ...

  • Page 542

    6c-16 power assisted steering system: 9 1) turn the ignition switch on with the eps control unit coupler disconnected, measure the voltage between terminal “a” and terminal “b” at the coupler. Special tool (a): 09900–25008 (multi-circuit tester set) tester knob indication voltage ( ) normal value (“...

  • Page 543

    Power assisted steering system: 6c-17 10 1) turn the ignition switch off. 2) short the mode select coupler terminals using the special tool. Special tool (a): 09930–82710 (mode select switch) 3) check for continuity between terminal “a” and terminal “b” at the coupler. Special tool (a): 09900–25008 ...

  • Page 544

    6c-18 power assisted steering system: dtc (diagnostic trouble code) output b931h26304004 note • even through the eps is operating correctly, a dtc is memorized in any of the following conditions. – previous malfunctions were repaired, but the dtcs were not deleted. • after carrying out dtc deleting ...

  • Page 545

    Power assisted steering system: 6c-19 understanding the dtc (diagnostic trouble code) a four-digit dtc is shown through the flashing pattern of the eps indicator light. A number between 1 and 9 is represented by the number of times that the eps indicator light lights up in interval of 0.3 seconds an...

  • Page 546

    6c-20 power assisted steering system: 3) read the dtc (diagnostic trouble code) and show data when trouble (displaying data at the time of dtc) according to instructions displayed on sds. Note • not only is sds used for detecting diagnostic trouble codes but also for reproducing and checking on scre...

  • Page 547

    Power assisted steering system: 6c-21 3) while the dtcs are being output, set the special tool to off. Caution ! The dtc deletion mode starts 11.5 seconds after the switch is set to off. 4) in the dtc deletion mode, switch the mode coupler switch off to on five times or more within 10 seconds, each ...

  • Page 548

    6c-22 power assisted steering system: 5) click the eps button (1). 6) click the “dtc inspection” button (2). 7) check the dtc. Note the previous malfunction history code (past dtc) still remains stored in the eps control unit. Therefore, erase the history code memorized in the eps control unit using...

  • Page 549

    Power assisted steering system: 6c-23 sds check b931h26304006 using sds, take the sample of data from the new vehicle and at the time of periodic maintenance at your dealer. Save the data in the computer or by printing and filing the hard copies. The saved or filed data are useful for troubleshootin...

  • Page 550

    6c-24 power assisted steering system: scroll the screen dtc table b931h26304007 * 1 : it goes off after running the engine. Check the motor current xx a check the motor current xx a check the motor current xx a i931h1630105-02 dtc malfunction cause indicator status reference none normal on * 1 — c11...

  • Page 551

    Power assisted steering system: 6c-25 dtc “c1111”: torque sensor (main) circuit malfunction b931h26304008 troubleshooting caution ! Never remove the torque sensor to prevent accident and damage. Note • after repairing the trouble, clear the dtc using a sds tool or mode coupler switch. Refer to “dtc ...

  • Page 552

    6c-26 power assisted steering system: step action yes no 1 1) turn the ignition switch off. 2) check the torque sensor coupler for loose or poor contact. If ok, measure the torque sensor input voltage. 3) disconnect the torque sensor coupler. 4) turn the ignition switch on. 5) measure the input volt...

  • Page 553

    Power assisted steering system: 6c-27 2 1) turn the ignition switch off. 2) connect the torque sensor coupler. 3) insert the needle pointed probes to lead wire coupler. 4) turn the ignition switch on. 5) measure the voltage between g wire “a” and b wire “b” by turning the handlebars left and right. ...

  • Page 554

    6c-28 power assisted steering system: dtc “c1113”: torque sensor (main / sub) circuit correlation malfunction b931h26304009 troubleshooting caution ! Never remove the torque sensor to prevent accident and damage. Note • after repairing the trouble, clear the dtc using a sds tool or mode coupler swit...

  • Page 555

    Power assisted steering system: 6c-29 step action yes no 1 1) turn the ignition switch off. 2) check the torque sensor coupler for loose or poor contact. If ok, measure the torque sensor input voltage. 3) disconnect the torque sensor coupler. 4) turn the ignition switch on. 5) measure the input volt...

  • Page 556

    6c-30 power assisted steering system: 1 6) next, measure the voltage between g wire “c” and ground, g wire “c” and b wire “b”, w wire “d” and ground and w wire “d” and b wire “b”. If the voltage of each measurement is 0 v ok. Special tool (a): 09900–25008 (multi-circuit tester set) tester knob indic...

  • Page 557

    Power assisted steering system: 6c-31 2 1) turn the ignition switch off. 2) connect the torque sensor coupler. 3) insert the needle pointed probes to lead wire coupler. 4) measure the torque sensor (main) voltage between g wire “a” and b wire “b”. Also, measure the torque sensor (sub) voltage betwee...

  • Page 558

    6c-32 power assisted steering system: dtc “c1114”: torque sensor power supply circuit malfunction b931h26304010 troubleshooting caution ! Never remove the torque sensor to prevent accident and damage. Note after repairing the trouble, clear the dtc using a sds tool or mode coupler switch. Refer to “...

  • Page 559

    Power assisted steering system: 6c-33 step action yes no 1 1) turn the ignition switch off. 2) check the eps control unit power source couplers for loose or poor contact. If ok, measure the torque sensor input voltage. 3) disconnect the torque sensor coupler. 4) turn the ignition switch on. 5) measu...

  • Page 560

    6c-34 power assisted steering system: dtc “c1115”: torque sensor (sub) circuit malfunction b931h26304011 troubleshooting caution ! Never remove the torque sensor to prevent accident and damage. Note after repairing the trouble, clear the dtc using a sds tool or mode coupler switch. Refer to “dtc (di...

  • Page 561

    Power assisted steering system: 6c-35 step action yes no 1 1) turn the ignition switch off. 2) check the torque sensor coupler for loose or poor contact. If ok, measure the torque sensor input voltage. 3) disconnect the torque sensor coupler. 4) turn the ignition switch on. 5) measure the input volt...

  • Page 562

    6c-36 power assisted steering system: 2 1) turn the ignition switch off. 2) connect the torque sensor coupler. 3) insert the needle pointed probes to lead wire coupler. 4) turn the ignition switch on. 5) measure the voltage between w wire “a” and b wire “b” by turning the handlebars left and right. ...

  • Page 563

    Power assisted steering system: 6c-37 dtc “c1121”: vehicle speed signal circuit malfunction b931h26304012 troubleshooting note after repairing the trouble, clear the dtc using a sds tool or mode coupler switch. Refer to “dtc (diagnostic trouble code) deleting (page 6c-20)”. Possible cause • faulty v...

  • Page 564

    6c-38 power assisted steering system: 1 6) disconnect the eps control unit coupler [b], speed sensor coupler [c] and combination meter coupler [a]. Refer to “speed sensor removal and installation: in section 9c” and “combination meter removal and installation: in section 9c”. 7) check the continuity...

  • Page 565

    Power assisted steering system: 6c-39 2 1) connect the combination meter coupler and speed sensor coupler. 2) measure the voltage between the bl/b wire “a” and ground. Special tool (a): 09900–25008 (multi-circuit tester set) tester knob indication voltage ( ) vehicle speed signal voltage 5.0 v is vo...

  • Page 566

    6c-40 power assisted steering system: dtc “c1122”: engine speed signal circuit malfunction b931h26304013 troubleshooting note start the engine after repairing the dtc and check that the indicator light is turned off. Refer to “precautions in diagnosing troubles (page 6c-1)”. Possible cause • faulty ...

  • Page 567

    Power assisted steering system: 6c-41 step action yes no 1 1) setup the sds tool (refer to the sds operation manual for further details.) or connect the mode select switch. 2) click “engine” and check the dtc code. Is not dtc “c12 (p0335)” displayed? Go to step 2. Inspect the ckp sensor. Refer to “d...

  • Page 568

    6c-42 power assisted steering system: 3 1) connect the ecm coupler. 2) start the engine. 3) measure the voltage between w wire “a” and ground. Special tool (a): 09900–25008 (multi-circuit tester set) tester knob indication voltage ( ) engine speed signal voltage it changes between 0 – 12 v is voltag...

  • Page 569

    Power assisted steering system: 6c-43 dtc “c1141”, “c1142”, “c1143”, “c1145” eps motor circuit malfunction b931h26304014 troubleshooting possible cause • faulty eps motor circuit. • faulty eps motor. • eps control unit malfunction. Step action yes no 1 1) turn the ignition switch off. 2) check the e...

  • Page 570

    6c-44 power assisted steering system: 2 1) turn the ignition switch off. 2) disconnect the eps motor coupler. 3) inspect the continuity of the eps motor. Refer to “eps motor inspection (page 6c-52)”. Is continuity ok? Replace the eps control unit with a known good one, and inspect it again. Refer to...

  • Page 571

    Power assisted steering system: 6c-45 dtc “c1153” eps control unit supply voltage circuit malfunction b931h26304015 troubleshooting possible cause • faulty regulator/rectifier. • faulty eps control unit. • faulty wire harness, etc. Step action yes no 1 1) remove the seat. Refer to “seat removal and ...

  • Page 572

    6c-46 power assisted steering system: 3 1) turn the ignition switch off. 2) check the eps control unit coupler for loose or poor contacts. If ok, then disconnect the eps control unit coupler. 3) start the engine at 5 000 r/min with the dimmer switch set to hi. 4) measure the voltage between terminal...

  • Page 573

    Power assisted steering system: 6c-47 dtc “c1152”, “c1154”, “c1155” eps control unit malfunction b931h26304016 troubleshooting • replace the eps control unit. Refer to “eps control unit removal and installation (page 6c-48)”. Repair instructions eps control unit construction b931h26306001 possible c...

  • Page 574

    6c-48 power assisted steering system: eps control unit removal and installation b931h26306002 removal 1) disconnect the battery (–) lead wire. 2) remove the front fender. Refer to “front side exterior parts removal and installation: in section 9d”. 3) disconnect the eps control unit couplers. 4) dis...

  • Page 575

    Power assisted steering system: 6c-49 • connect the torque sensor lead wire (2). • connect the eps motor coupler (3) and clamp (4). • connect the other eps control unit couplers. • install the front fender. Refer to “front side exterior parts removal and installation: in section 9d”. Eps body assemb...

  • Page 576

    6c-50 power assisted steering system: 8) remove the steering shaft plate (7) with the special tool. Special tool (a): 09944–36011 (steering wheel remover) 9) remove the front brake hose union (8) from the cable guide (9). 10) remove the steering shaft bolt (10). 11) remove the eps body assembly moun...

  • Page 577

    Power assisted steering system: 6c-51 • install the cable guide (1) and tighten the bolts (2) to the specified torque. Tightening torque eps body assembly mounting bolt (a): 26 n·m ( 2.6 kgf-m, 19.0 lbf-ft) • tighten the eps body assembly mounting nuts (3) to the specified torque. Tightening torque ...

  • Page 578

    6c-52 power assisted steering system: • install the handlebar holder (7) and tighten the nuts to the specified torque. Tightening torque handlebar holder nut (e): 60 n·m (6.0 kgf-m, 43.5 lbf-ft) • install the center cover (8). • install the holder cover (12). • install the front fender. Refer to “fr...

  • Page 579

    Power assisted steering system: 6c-53 specifications tightening torque specifications b931h26307001 note the specified tightening torque is described in the following. “eps control unit construction (page 6c-47)” reference: for the tightening torque of fastener not specified in this section, refer t...

  • Page 580

    6c-54 power assisted steering system: special tool b931h26308002 09900–25008 09900–25009 multi circuit tester set needle pointed probe set )(page 6c-10) / )(page 6c-10) / )(page 6c-12) / )(page 6c-13) / )(page 6c-13) / )(page 6c-15) / )(page 6c-16) / )(page 6c-17) / )(page 6c-26) / )(page 6c-27) / )...

  • Page 581: Section 9

    Table of contents 9- i 9 section 9 contents body and accessories precautions .................................................9-1 precautions............................................................. 9-1 precautions for electrical system ......................... 9-1 component location .............

  • Page 582

    9-ii table of contents specifications....................................................... 9e-7 tightening torque specifications........................ 9e-7 special tools and equipment .............................9e-7.

  • Page 583: Precautions

    Precautions: 9-1 body and accessories precautions precautions precautions for electrical system b931h29000001 refer to “general precautions: in section 00” and “precautions for electrical circuit service: in section 00”. Component location electrical components location b931h29003001 refer to “elect...

  • Page 584: Wiring Systems

    9a-1 wiring systems: body and accessories wiring systems schematic and routing diagram wiring diagram b931h29102001 refer to “wire color symbols: in section 0a”..

  • Page 585

    Wiring systems: 9a-2 for p-17 p p at map on off on off on2 on1 off 2wd 4wd lock on off hi lo run off on off on off push push 12 3 4 56 1 m diff-lock rela y cooling fa n thermo- switch cooling fa n mot or brake lever switch set secede emergency switch horn horn butt on ignition switch p arking brake ...

  • Page 586

    9a-3 wiring systems: for p-24, 28, 33 p p at map on off on off on2 on1 off 2wd 4wd lock on off hi lo run off on off on off push push 12 3 45 6 1 m diff-lock rela y cooling fa n thermo- switch cooling fa n mot or brake lever switch horn horn butt on ignition switch p arking brake switch 4wd/diff-lock...

  • Page 587

    Wiring systems: 9a-4 wiring harness routing diagram b931h29102002 “ b ” 2 3 3 “a” 2 1 4 7 6 5 view a “a” 1 “ a ” “ b ” 1 1 “ c ” “c” 8 9 “b” 7 i931h1910901-07 1. Clamp 9. Throttle cable 2. Clamp : bind the wiring harness and hose with the clamp. “a”: pass the wiring harness and cooling fan lead wire...

  • Page 588

    9a-5 wiring systems: “f” “a” 1 2 (b) (a) 3 5 4 8 6 11 “b” 14 13 16 17 15 7 9 12 “c” view a view f 18 10 “e” “d” 11 i931h1910902-07 1. Starter motor 13. Ect sensor coupler 2. Starter motor terminal 14. Injector coupler 3. Engine earth 15. Iap/tp/iat sensor coupler 4. Clamp : bind the wiring harness a...

  • Page 589

    Wiring systems: 9a-6 3 “ a ” 5 7 8 9 10 11 12 “a” view 4 2 4 2 lh rh “c” 14 13 6 1 “a” “d” “b” i931h1910903-05 1. Clamp : bind the left handlebar switch lead wire, rear brake lever switch lead wire, horn lead wire (for p-17, 24) and emergency switch lead wire (for p-17) with the clamp. Cut the tip o...

  • Page 590

    9a-7 wiring systems: specifications service data b931h2910s001 electrical unit: mm tightening torque specifications b931h2910s002 note the specified tightening torque is described in the following. “wiring harness routing diagram (page 9a-4)” reference: for the tightening torque of fastener not spec...

  • Page 591: Lighting Systems

    Lighting systems: 9b-1 body and accessories lighting systems repair instructions headlight components b931h29206001 headlight removal and installation b931h29206002 removal 1) remove the front grill upper cover. Refer to “front side exterior parts removal and installation: in section 9d”. 2) disconn...

  • Page 592

    9b-2 lighting systems: installation install the headlight in the reverse order of removal. Pay attention to the following point: • after installing, be sure to inspect the headlight beam. Refer to “headlight beam adjustment (page 9b-2)”. Headlight bulb replacement b931h29206003 caution ! • if you to...

  • Page 593

    Lighting systems: 9b-3 rear combination light removal and installation b931h29206006 removal 1) remove the rear combination light mounting bolts. 2) remove the rear combination light assembly by disconnecting the clamp (1) and coupler (2). Installation install the rear combination light in the rever...

  • Page 594

    9b-4 lighting systems: reversing light bulb replacement (for p-17) b931h29206008 remove the reversing light bulb (1) as shown in the figure. Reversing light relay inspection (for p-17) b931h29206009 first, check the insulation between “a” and “b” terminals with the multi-circuit tester. Then apply 1...

  • Page 595

    Lighting systems: 9b-5 specifications service data b931h29207001 wattage unit: w special tools and equipment special tool b931h29208001 item specification p-24, 28, 33 p-17 headlight hi 35 x 2 ← lo 35 x 2 ← brake light/taillight 21/5 ← reversing light — 21 09900–25008 multi circuit tester set )(page...

  • Page 596

    9c-1 combination meter / fuel meter / horn: body and accessories combination meter / fuel meter / horn general description combination meter system description b931h29301001 this combination meter mainly consists of lcd (liquid crystal display) and led (light emitting diode). The lcds indicate speed...

  • Page 597

    Combination meter / fuel meter / horn: 9c-2 repair instructions combination meter components b931h29306001 combination meter removal and installation b931h29306002 caution ! When disconnecting and reconnecting the combination meter coupler, make sure to turn off the ignition switch, or electronic pa...

  • Page 598

    9c-3 combination meter / fuel meter / horn: 2) remove the combination meter mounting bolt. 3) disconnect the combination meter coupler (5) and remove the combination meter assembly. Installation install the combination meter in the reverse order of removal. Pay attention to the following points: • m...

  • Page 599

    Combination meter / fuel meter / horn: 9c-4 3) disconnect the ect sensor coupler (1). 4) connect the variable resistor (2) between the terminals. 5) turn the ignition switch on. 6) check the lcd and led operations when the resistance is adjusted to the specified values. If either one or all indicati...

  • Page 600

    9c-5 combination meter / fuel meter / horn: 3) connect the variable resister (2) between the y/b and b lead wires from the wire harness. 4) turn the ignition switch on. 5) check the display of fuel level indicator (lcd) as shown in the figure. If any abnormality is found, replace the combination met...

  • Page 601

    Combination meter / fuel meter / horn: 9c-6 speedometer inspection b931h29306009 if the speedometer, odometer or trip meter does not function properly, inspect the speed sensor and the coupler connections. If the speed sensor and coupler connections are ok, replace the combination meter unit with a ...

  • Page 602

    9c-7 combination meter / fuel meter / horn: 3) move a screwdriver back and forth across the pick- up surface of the speed sensor. The voltage readings should cycle as follows (0 v → 12 v or 12 v → 0 v). If the voltage reading does not change, replace the speed sensor with a new one. Note while testi...

  • Page 603

    Combination meter / fuel meter / horn: 9c-8 horn removal and installation (for p-17, 24) b931h29306015 removal disconnect the horn couplers and remove the horn by removing the mounting nut as shown in the wiring harness routing diagram. Refer to “wiring harness routing diagram: in section 9a”. Insta...

  • Page 604: Exterior Parts

    9d-1 exterior parts: body and accessories exterior parts repair instructions exterior parts construction b931h29406001 front side 1 2 3 4 7 5 6 i931h1940040-04 1. Front fender 3. Air cleaner box cover 5. Front grill cover 7. Right inner fender 2. Front box 4. Side cover 6. Left inner fender.

  • Page 605

    Exterior parts: 9d-2 rear side 1 2 3 4 5 i931h1940041-02 1. Rear fender 2. Right mud guard 3. Left mud guard 4. Engine side cover 5. Rear box.

  • Page 606

    9d-3 exterior parts: rear fender heat shield construction b931h29406002 “ a ” 2 1 2 “ a ” “ b ” “ c ” “ d ” fwd fwd 2 “a” i931h1940042-01 1. Rear fender “a”: 1 – 3 mm (0.04 – 0.12 in) “c”: 67 mm (2.64 in) “a”: inside of the rear fender. 2. Heat shield “b”: 5 mm (0.2 in) “d”: 8 mm (0.3 in).

  • Page 607

    Exterior parts: 9d-4 fuel tank lower cover heat shield installation b931h29406003 1 2 1 “ a ” 3 2 1 1 i931h1940044-01 1. Heat shield 2. Cushion 3. Fuel tank lower cover “a”: max. 5 mm (0.2 in).

  • Page 608

    9d-5 exterior parts: fastener removal and installation b931h29406004 type a removal 1) depress the head of fastener center piece (1). 2) pull out the fastener (2). Installation 1) let the center piece stick out toward the head so that the pawls “a” closes. 2) insert the fastener into the installatio...

  • Page 609

    Exterior parts: 9d-6 front side exterior parts removal and installation b931h29406005 front grill cover removal remove the front grill cover (1) by removing the fasteners (2). Installation install the front grill cover in the reverse order of removal. Air cleaner box cover removal 1) remove the seat...

  • Page 610

    9d-7 exterior parts: 5) remove the front box holder (4) and cushions (5). Installation install the front box in the reverse order of removal. Pay attention to the following points: • when installing the cushion, fit the convex parts “a” of the cushion onto the concave parts “b” of the front box. • w...

  • Page 611

    Exterior parts: 9d-8 installation install the side cover in the reverse order of removal. Front fender removal 1) remove the front carrier. Refer to “front carrier removal and installation: in section 9e”. 2) remove the seat. Refer to “seat removal and installation (page 9d-11)”. 3) remove the air c...

  • Page 612

    9d-9 exterior parts: rear side exterior parts removal and installation b931h29406006 engine side cover removal remove the engine side cover (1). Installation install the engine side cover in the reverse order of removal. Rear box removal remove the rear box (1). Installation install the rear box in ...

  • Page 613

    Exterior parts: 9d-10 2) remove the fasteners (3), bolt (4) and screw (5). 3) move the rear fender upside. 4) remove the fuel tank outer cover (6). Installation install the fuel tank outer cover in the reverse order of removal. Rear fender removal 1) remove the rear carrier. Refer to “rear carrier r...

  • Page 614

    9d-11 exterior parts: 9) remove the parking brake cable (8) from the cable guide. 10) remove the fuel tank cap (9). Caution ! To prevent the fuel tank from contamination with foreign particles, install the fuel tank cap, after removing the rear fender. 11) remove the rear fender (10). Installation i...

  • Page 615

    Exterior parts: 9d-12 under cover components b931h29406008 under cover removal and installation b931h29406009 front under cover removal remove the front under cover (1) by removing the bolts (2) and fasteners (3). Installation 1) fix the front under cover “b” to the groove “a” of engine under cover....

  • Page 616

    9d-13 exterior parts: 2) install the front under cover. Engine under cover removal remove the engine under cover (1). Installation 1) fix the engine under cover (1) with the front under cover (2) and rear under cover (3). 2) install the engine under cover. Rear under cover removal remove the rear un...

  • Page 617: Body Structure

    Body structure: 9e-1 body and accessories body structure repair instructions body frame construction b931h29506001 fwd fwd 1 2 3 4 4 i931h1950018-02 1. Frame 3. Washer : apply thread lock to the thread part. 2. Battery plate 4. Spacer.

  • Page 618

    9e-2 body structure: footrest construction b931h29506002 footrest removal and installation b931h29506003 removal 1) remove the mud guard. Refer to “rear side exterior parts removal and installation: in section 9d”. 2) remove the rear brake cable clamp (1) (rh). 3) remove the footrest (2) (rh & lh). ...

  • Page 619

    Body structure: 9e-3 carrier construction b931h29506004 front carrier removal and installation b931h29506005 removal 1) remove the front grill upper cover. Refer to “front side exterior parts removal and installation: in section 9d”. 2) remove the front carrier (1) by removing the bolts (2). Fwd fwd...

  • Page 620

    9e-4 body structure: installation install the front carrier in the reverse order of removal. Pay attention to the following point: • apply thread lock to the front carrier mounting bolts. : thread lock cement 99000–32030 (thread lock cement super 1303 or equivalent) rear carrier removal and installa...

  • Page 621

    Body structure: 9e-5 front grip bar construction b931h29506007 front grip bar removal and installation b931h29506008 removal 1) remove the front carrier. Refer to “front carrier removal and installation (page 9e-3)”. 2) remove the front grill cover. Refer to “front side exterior parts removal and in...

  • Page 622

    9e-6 body structure: trailer towing construction b931h29506009 trailer towing removal and instruction b931h29506010 removal remove the trailer towing (1). Installation install the trailer towing with the trailer towing mounting bolts and then tighten them to the specified torque. Tightening torque t...

  • Page 623

    Body structure: 9e-7 specifications tightening torque specifications b931h29507001 note the specified tightening torque is described in the following. “footrest construction (page 9e-2)” “trailer towing construction (page 9e-6)” reference: for the tightening torque of fastener not specified in this ...

  • Page 624

    Prepared by december, 2008 part no. 99500-44080-03e printed in u.S.A. 624.